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Variable Speed Drive Service Manual Edition: February 2011 SD70MS01CI Rev. C SD700 POWER ELECTRONICS SAFETY SYMBOLS Always follow safety instructions to prevent accidents and potential hazards from occurring. WARNING CAUTION This symbol means inadequate operation and may result in serious personal injuries or death. This symbol Identifies shock hazards under certain conditions. Particular attention should be given as dangerous voltage might be present. Maintenance operation should be done by qualified personnel Identifies potential hazards under certain conditions. Read the message and follow the instructions carefully. Identifies shock hazards under certain conditions. Particular attention should be given as dangerous voltage might be present. Edition of February 2011 This edition could present technical imprecisions or misprints. The information here included will be periodically modified and updated, and all those modifications will be incorporated in later editions. In order to consult the most updated information of this product, you might access our website www.power-electronics.com , where the latest version of this manual can be downloaded. 2 SERVICE MANUAL SD700 POWER ELECTRONICS INDEX SAFETY INSTRUCTIONS ........................................................................................................... 1. INTRODUCTION ................................................................................................................ 8 1.1. About this manual .................................................................................................... 8 1.2. Who should inerrtake service ................................................................................... 9 1.3. Level of servicing ..................................................................................................... 9 1.4. Notes........................................................................................................................ 9 2. BEFORE STARTING TESTING OR SERVICE WORK. .................................................. 10 3. PRINTED BOARD DESCRIPTIONS ............................................................................... 11 3.1. Input Rectifier. ........................................................................................................ 11 3.2. Output Inverter Bridge ............................................................................................ 11 3.3. Power PCB ............................................................................................................ 11 3.4. Control PCB ........................................................................................................... 11 4. FAULT MESSAGES. DESCRIPTIONS AND ACTIONS .................................................. 12 4.1. Introduction ........................................................................................................... 12 4.2. Faults List............................................................................................................... 12 4.3. Display fault ........................................................................................................... 22 4.4. Fuses fault ............................................................................................................. 23 4.5. Indicator Leds ........................................................................................................ 35 5. CONNECTIONS ............................................................................................................... 55 5.1. Power PCB ............................................................................................................ 55 5.2. Control PCB ........................................................................................................... 57 6. TESTING .......................................................................................................................... 58 6.1. Testing the rectifier and inverter. ............................................................................ 58 6.2. Individual SCR testing. ........................................................................................... 60 6.3. Testing the DC Bus Capacitor. ............................................................................... 60 6.4. Individual IGBT test ................................................................................................ 60 6.5. Soft Powering After Repair..................................................................................... 61 6.6. Checking external inputs ....................................................................................... 62 7. SUBASSEMBLY AND REPLACEMENT ........................................................................ 64 7.1. Frame 1.................................................................................................................. 64 7.2. Frame 2.................................................................................................................. 72 7.3. Frame 3 (60 – 75) .................................................................................................. 84 7.4. Frame 3 (90 – 115) ................................................................................................ 99 7.5. Frame 4................................................................................................................ 115 7.6. Frame 5................................................................................................................ 132 7.7. Frame 6................................................................................................................ 149 7.8. Frame 7................................................................................................................ 164 7.9. Frame 8................................................................................................................ 180 5 SERVICE MANUAL 3 SD700 8. PARTS LIST 8.1. 8.2. 8.3. 8.4. 8.5. 9. 4 POWER ELECTRONICS Frame 4................................................................................................................ 196 Frame 5................................................................................................................ 199 Frame 6................................................................................................................ 201 Frame 7................................................................................................................ 203 Freme 8................................................................................................................ 205 BLOCK DIAGRAM ......................................................................................................... 207 9.1. Frame 4................................................................................................................ 208 9.2. Frame 5................................................................................................................ 209 9.3. Frame 6................................................................................................................ 210 9.4. Frame 7................................................................................................................ 211 9.5. Frame 8................................................................................................................ 212 SERVICE MANUAL SD700 POWER ELECTRONICS SAFETY INSTRUCTIONS IMPORTANT! Read this manual carefully to maximize the performance of this product and to ensure its safe use. In this manual, safety messages are classified as follows: WARNING Do not remove the cover while power is applied or the unit is in operation. Otherwise electric shock could occur. Do not run the drive without the front cover. Otherwise you may get an electric shock due to the high voltage terminals or to the exposure of charged capacitors. Do not remove the cover except for periodical inspections or wiring, even if the input power is not applied. Otherwise you may access the charged circuits and suffer an electric shock. Wiring and periodic inspections should be performed at least 10 minutes after disconnecting the input power and after checking the DC Link voltage is discharged with a meter (below 30VDC).Otherwise you may suffer an electric shock. Operate the switches with dry hands. Otherwise you may suffer an electric shock. Do not use cables with damaged insulation. Otherwise you may suffer an electric shock. Do not subject the cables to abrasions, excessive stress, heavy loads or pinching. Otherwise, you may suffer an electric shock. SERVICE MANUAL 5 SD700 POWER ELECTRONICS CAUTION Install the drive on a non-flammable surface. Do not place flammable material nearby. Otherwise fire could occur. Disconnect the input power if the drive gets damaged. Otherwise it could result in a secondary accident or fire. After the input power is applied or removed, the drive will remain hot for a couple of minutes. Touching hot parts may result in skin burns. Do not apply power to a damaged drive or to a drive with parts missing even if the installation is complete. Otherwise you may suffer an electric shock. Do not allow lint, paper, wood chips, dust, metallic chips or other foreign matter into the drive. Otherwise fire or accident could occur. WARNINGS SAFETY Wear safety glasses when operating the drive with power applied and the front cover is removed. Handle the drive with care according to its weight. Install the drive according to the instructions incuded in this manual. Do not place heavy objects on the drive. Ensure that the mounting orientation is correct. Do not drop the drive or subject it to impact. The SD700 drives contain static sensitive printed circuits boards. Use static safety procedures when handling these boards. CONNECTION PRECAUTIONS For EMERGENCY STOP, make sure supply circuitry is open. Do not disconnect motor cables if input power supply remains connected. The internal circuits of the SD700 series will be damaged if the incoming power is connected and applied to output terminals (U, V, W). Always check whether the DC Link LED is OFF before wiring terminals. The capacitors may hold high-voltage even after the input power is disconnected. Use caution to prevent the possibility of personal injury. TRIAL RUN Verify all parameters before operating the drive. Alteration of parameters may be required depending on application and load. Always apply voltage and current signals to each terminal that are within levels indicated within this manual. Otherwise, damage to the drive may result. 6 SERVICE MANUAL SD700 POWER ELECTRONICS EARTH CONNECTION The drive is a high frequency switching device and leakage current may flow. Ground the drive to avoid electrical shock. Use caution to prevent the possibility of personal injury. Connect only to the dedicated ground terminal of the drive. Do not use the case or the chassis screw for grounding. When installing, grounding wire should be connected the first and removed the last. Motor ground must be connected to the drive ground terminal and not to the installation‟s ground. We recommend that the section of the ground connection cable should be equal or higher than the active conductor. Installation ground must be connected to the drive ground terminal. SERVICE MANUAL 7 SD700 POWER ELECTRONICS 1. INTRODUCTION 1.1. About this manual This manual refers to the SD700 Variable Speed Drive. Specific models are shown in Table 1. 380V SD700905X SD701155X SD701505X SD701705X SD702105X SD702505X SD703305X SD703705X SD704605X SD705805X SD706505X SD707205X SD708405X SD709255X SD710305X SD711505X SD712605X SD714405X SD715805X SD718005X SD722005X FRAME 4 FRAME 5 FRAME 6 FRAME 7 FRAME 8 FRAME 9 FRAME 10 FRAME 11 690V SD700526X SD700626X SD700806X SD701056X SD701306X SD701506X SD701706X SD702106X SD702606X SD703206X SD703856X SD704606X SD705506X SD706606X Note 1: All drives of frame 9 are obtained by assembling 3 models of frame 6. Note 2: All drives of frame 10 are obtained by assembling 3 models of frame 7. Note 3: All drives of frame 11 are obtained by assembling 3 models of frame 8. 380V 690V SD710305x SD711505x SD712605x SD714405x 3 x SD703705x 3 x SD703705X 3 x SD704605X 3 x SD704605X SD707506x SD708406x SD709506x 3x SD702106X 3x SD702106X 3x SD702606X FRAME 10 SD715805x SD718005x 3 x SD705805X 3 x SD706505X SD711406x SD712706x SD714206x FRAME 11 SD722005x 3 x SD708405X SD715006x SD718006x 3x SD703856X 3x SD704606X 3x SD704606X 3x SD705506X 3x SD706606X FRAME 9 This manual outlines all the procedures for a field testing, repair and re-powering of a faulty SDrive. It is not intended as a commissioning guide. Refer to the SD700 Getting Started Manual for commissioning information. 8 SERVICE MANUAL POWER ELECTRONICS SD700 1.2. Who should undertake service Servicing of an SD700 should be only undertaken by suitably qualified or experienced technicians. The service personnel should be qulified in the principles of power electronics. 1.3. Level of servicing All the SD700 covered in this manual are built on a modular basis. These modules are designed to be disassembled and replaced as necessary to perform repair. A list of available spare parts and modules is in Section 8 of this manual. Printed circuit board assemblies are not designed to be serviced as components. They are usually complex and require special test equipment for servicing. 1.4. Notes It is the integrator‟s responsibility to ensure the configuration and installation of the SD700 meets the requirements of any specific site, local and national electrical regulations. It is the responsibility of the end user/purchaser to ensure that operators understand how to use this equipment safely. Please read this manual carefully. SERVICE MANUAL 9 SD700 2. POWER ELECTRONICS BEFORE STARTING TESTING OR SERVICE WORK. Site Preparation The SD700 is best serviced on a bench, if it is possible. The working area in front of the SD700 must be clean and tidy, especially while servicing the biggest and heaviest SD700 sizes. Flat surfaces for placing parts on and containers for small items like screws and bolts will be necessary. Tools requirements No.2 Phillips screwdriver No.3 Phillips screwdriver 17 mm nut drivers 13 mm nut drivers 10 mm nut drivers Multimeter upto 1000V AC and DC maximum. Variac Safety and Testing Before Starting Repairs 10 1) Isolate and lock out the mains supply to the SD700 and any low voltage supply that may be in parallel with the control power supply. 2) Allow approximately 5 minutes for the DC Bus capacitors to be discharged. 3) Test between input terminals L1, L2, L3 and L1, L2, L3 to earth to ensure the supply has been disconnected. 4) Test between the HVDC (+) and HVDC (-) Bus terminals to ensure the DC Bus has been fully discharged. INSTALLATION AND CONNECTION SD700 POWER ELECTRONICS 3. PRINTED CIRCUIT BOARD DESCRIPTIONS 3.1. Input Rectifier. The three phases mains supply the rectifier circuit through terminals L1, L2, L3. Each input supplies through a high speed fuse and one winding on a three phase AC choke. The input rectifier is a three phase half controlled bridge circuit, with three diode/SCR modules. Each SCR module has a Snubber PCB. This PCB restricts the current to avoid a damage in the circuits and smooths the commutations of each diode/SCR. This PCB has also incorporated a circuit to control the current, which charges the DC Bus. The output of the rectifier supplies to the DC Bus. The DC Bus has a bank of capacitors. This capacitors are joined in series in parallel. For 400 Vac input, the DC Bus output on no loads is approximately 565 V dc . Wire-wound resistors are fixed across the capacitors in order to share voltage of the series capacitors. 3.2. Output Inverter Bridge. The DC Bus supplies to the three phases of the inverter bridge, which is composed of 3 IGBTs(Insolated gate bipolar transistors). The IGBTs modulate the required three phases output waveform to supply to the motor through terminals U, V, W. The Current Transformers ( DCCT) and the Output Chokes are placed In the middle of the IGBTs and the output terminals U, V, W. The IGBTs are protected by two PCBs, the gate drive PCBs. The upper gate drive controls the IGBTs logic pulses, and detects an IGBT desaturation. The lower Gate Drive contains the shot resistors and the protection varistors. 3.3. Power PCB This PCB contains the following circuits: - Switch mode Power supply: generates all required DC voltages. - SCR pulses generation: generates the SCR firing pulses for soft charge ramp. - Protections: Protections for a high and low Bus voltage, shortcircuits and high temperature. - Drive Select module: It is plugged to the power PCB, shows the rating identification, and scales the DCCT outputs for relaying to the control PCB. 3.4. Control PCB This PCB generates the waveform; control input and output processing, mode selection and parameters setting. It also controls an alphanumeric display and keypad for user interface. SERVICE MANUAL 11 SD700 4. POWER ELECTRONICS FAULT MESSAGES. DESCRIPTIONS AND ACTIONS 4.1. Introduction When a fault occurs, the SD700 will stop the motor and show a fault in the display. You can display this fault in the programming line (lower line) while motor current and the speed values are displayed in the upper line at the moment of the fault. It is possible to navigate through the additional display lines to access other status parameters without resetting the fault. These additional status parameters offer further information about the moment, when the fault occurred. Additionally, the FAULT led will blink and the fault message will be displayed until the fault is over and the drive is reset. Figure 1.1 Fault displaying - Programming Line 4.2. Faults List Fault: I LIM FLT Description: Output current has reached a dangerous level. The value is above 220% of the drive rated current. Protection is activated instantaneously. Possible cause: Motor output short circuit; Wiring fault; Circuit fault; Motor fault. Actions: Check output cables and motor for possible wiring faults or short circuits. Fault: F2 V LIM FLT Description: DC Bus voltage has reached a dangerous level >850Vdc. Hardware Protection. Drive will cut off the output to the motor. Possible cause: High voltage peak on the input; High load regeneration; Deceleration ramp too high 12 SERVICE MANUAL SD700 POWER ELECTRONICS Actions: Check conditions of input power supply. Decrease deceleration ramps (parameters „G5.2 DECEL1‟ and „G5.4 DECEL2‟). Fault: F3 PDINT FLT Description: Bus voltage and the output current of the device have reached dangerous levels. Possible cause: See faults F1 and F2. Actions : See faults F1 and F2. Fault: F4 U+ DESAT; F5 U- DESAT; F6 V+ DESAT; F7 V- DESAT; F8 W+ DESAT; F9 W- DESAT Description: An Internal protection tripped within the IGBT semiconductors. Possible cause: Short circuit; Extreme overcurrent, overload; Wiring fault; circuit fault; Desaturation of IGBT; IGBT fault. Actions: Check if there are possible wiring faults or a motor fault. If the fault persists after disconnecting output wires, Check IGBTs (section 6.4) Fault: F10 NEG DESAT Description: An automatic internal protection of several of the IGBT semiconductors tripped. Possible cause: Short circuit; Extreme overcurrent; device overload; Desaturation of IGBT; IGBT fault. Actions: Check conditions of input power supply and wiring conditions. Check the Fuse 4 in the Power PCB (section 4.4.2) Fault: F11 VIN LOSS Description: Power supply loss of any input phase for a time higher than 20ms occurred. Possible cause: Input power is incorrect, damaged fuses; Input wiring is incorrect; Actions: Check conditions of input power supply; Check wiring; Check input Fuse (section 4.4.1) Fault: F12 IMB V IN Description: Power supply loss of any input phase for a time higher than 20ms has occurred. Possible cause: Input power is incorrect, damaged fuses. Actions: Check conditions of input power supply; Check wiring; Check input Fuse (section 5.4.1); Check Fuses of Snubber PCB (section 4.4.3) Fault: F13 HI V IN Description: Input voltage imbalance higher than ±10% of average input power supply of SD700 for a time higher than 100ms. Possible cause: Input power is incorrect; Incorrect setting of parameter „G11.6 HIGH VOLT‟ Actions: Check input power conditions; Check parameters settings; SERVICE MANUAL 13 SD700 POWER ELECTRONICS Fault: F14 LW V IN Description: Average supply voltage is lower than the value set in „G11.4 LOW VOLT‟ for a longer time than the one set in „G11.5 LOW V TO‟ Possible cause: Input power is incorrect, damaged fuses; Incorrect setting of parameter „G11.4 LOW VOLT‟. Actions: Check input Fuse (section 4.4.1); Check Fuses of Snubber PCB (section 5.4.3); Check input power conditions; Check parameters settings. Fault: F15 CURL Vdc Description: Unstable bus voltage. There is a DC Bus voltage ripple higher than 100Vdc for more than 1.1 seconds. Possible cause: Input power is incorrect; Motor is driving an unstable load; Actions: Check input power conditions, load type of the application, and all the motor mechanical parts. If the fault persists after disconnecting output wires, check rectifiers (section 6.1) and check IGBTs (section 6.4) Fault: F16 HI Vdc Description: DC Bus voltage has exceeded critical operating level (>850Vdc). Software Protection. Possible cause: High voltage peak at the input; High load regeneration; Deceleration ramp too high Actions: Check conditions of input power supply; Check stop conditions of the drive; Decrease deceleration ramps (parameters „G5.2 DECEL1‟ and „G5.4 DECEL2‟). Fault: F17 LW Vdc Description: DC Bus voltage is lower than the critical operating level (<350Vdc). Possible cause: Input power is wrong, damaged fuses. Actions: Check conditions of input power supply; Check input Fuse (section 4.4.1); If the fault happens when the device is loaded, check that the DC Bus voltage doesn‟t fall down. If the voltage falls down might be due to a fault in the rectifiers (section 6.1) Fault: F18 IMB V OUT Description: Voltage imbalance higher than ±5% of the average drive output voltage for a time longer than 100ms. Possible cause: Motor is driving an unstable load; Motor wiring fault; Motor is wrong Actions: Check motor circuit completely in case of possible wiring faults or motor fault. If the fault persists after disconnecting output wires, change Power PCB 14 SERVICE MANUAL SD700 POWER ELECTRONICS Fault: F19 IMB I OUT Description: Current imbalance of more than ±25% of the average output motor current for a time longer than 1s. Possible cause: Motor is supporting unstable loads; Motor wiring fault; Motor is wrong. Actions: Check motor circuit completely in case of possible wiring faults or motor fault. Compare the current at the output with the current shown in the display. If the current is different, change the Power PCB. Fault: F20 GROUND FLT Description: Current level to the ground has exceeded the level set in „G11.3 GND I LIMT‟. Possible cause: Motor or wiring has short-circuited to ground; Ground is incorrectly connected or wrong. Actions: Disconnect the motor and wiring of the SD700 and check motor insulation; Check and improve the ground connection system. Fault: F21 I LIM T/O Description: Motor current has exceeded the current limit set in „G10.5 I LIMIT‟ for the time set in „G10.6 I LIM TO‟. Possible cause: Motor stalled. Heavy load; Motor mechanical brake is coupled. Actions: Check the motor load; Increase maximum current limit. Fault: F22 TQ LIM T/O Description: Motor torque has exceeded the torque limit set in parameter „G10.7 MAX TOR‟ for the time set in „G10.8 T LIMT TO‟. Possible cause: Motor stalled. Heavy load; Motor mechanical brake is coupled. Actions: Check the motor load; Increase maximum current limit. Fault: F25 MTR O/L Description: Motor overload calculated by SD700 thermal model has exceeded 110%. Possible cause: High current injected to the motor due to heavy load; The load exceeds the capacity of motor cooling under normal operating conditions; Incorrect setting of the thermal model parameters; Phase loss of the motor or a fault in motor windings. Actions: Check the motor load. Check the setting of parameters „G2.1 MTR CUR‟ and „G2.7 MTR COOL‟ related to the motor thermal model. Increasing the parameter „G2.7 MTR COOL‟, can be undertaken when there is a motor PTC fitted and it is connected to the SD700. Fault: F27 DL SMTH Descrtiption: DC Bus has not been charged in the expected time SERVICE MANUAL 15 SD700 POWER ELECTRONICS Posible cause: Potential damage to the soft charge resistors of the SD700. Actions: Try to reset the fault. Disconnect and re-connect again the input power. If the fault persists check rectifiers (section 6.1) Fault: F28 MICRO FLT Descrtiption: Microprocessor has detected wrong data. Posible cause: Input power fault; Parameters setting is not recognised. Actions: Disconnect and re-connect the SD700 input power of the drive. If the same fault appears, initialize all of the parameters (parameter „G1.5 INITIALISE‟) and connect the input power again. If the fault persists, change Control PCB Fault: F29 DSP FLT Descrtiption: DSP has detected wrong data. Posible cause: Input power fault; Parameters setting is not recognised Actions: Disconnect and connect again SD700 input power. If the same fault appears, initialize all the parameters (parameter „G1.5 INITIALISE‟) and connect the input power again. If the fault persists, change Control PCB Fault: F30 WATCHDOG Descrtiption: An unknown fault has reseted the microprocessor of the control board. Posible cause: Input power fault. Actions: Reset the fault; If the fault persists, change Control PCB Fault: F31 SCR L1; F32 SCR L2; F33 SCR L3 Descrtiption: Trip on conduction status of thyristor 1, 2 or 3. The thyristor has not turned on correctly Posible cause: A conduction fault occurred in the corresponding thyristor. The thyristor is OFF when it should be on. Actions: Try to reset the fault. Disconnect and re-connect the input power. If the fault persists check Fuses of Snubber PCB (section 4.4.3) Fault: F35 PHSE L1 LOSS; F36 PHSE L2 LOSS; F37 PHSE L3 LOSS Descrtiption: Input phase L1, L2 or L3 is not present. Phase fault. Posible cause: Input phase L1, L2 or L3 is not connected correctly or there is no voltage on it. Actions: Verify the wiring of the input power supply of the drive. Check input voltage and input fuses. If the fault persists Fault: F40 EXT / PTC 16 SERVICE MANUAL SD700 POWER ELECTRONICS Descrtiption: External trip or motor PTC device has operated (terminals 8 and 9). Values out of the range might (85Ω to 2KΩ) generate this fault. Posible cause: External trip device has operated; Motor is overheated (motor load exceeds the cooling capacity at operating speed); Fault in sensor connection. Actions: Check the external trip switch (if exists); Check motor temperature.To reset the fault the motor must be return to normal temperature; Check sensor wiring. Check input Fuse (section 4.4.1) Fault: F41 COMMS TRIP Descrtiption: Trip generated through RS232 or RS485 communication. Master (PLC or PC) is generating a fault in the SD700 through serial communication. Posible cause: Trip generated by a computer through serial communication. Actions: Disconnect the SD700 from the communication network and verify if the fault is generated again. If the fault persists, change Control PCB. Fault: F42 AIN1 LOSS Descrtiption: The SD700 is not receiving any signal in the analogue input 1 and „G4.2.14 AIN1 LOSS‟ is set „Yes‟. The signal connected to this input has been lost. Posible cause: Analogue input cable has come loose or disconnected (terminals 10 and 11). Actions: Verify the wiring and the device, which provides the analogue signal. If the fault persists, change Control PCB. Fault: F43 AIN2 LOSS Descrtiption: The SD700 is not receiving any signal in the analogue input 2 and „G4.2.14 AIN1 LOSS‟ is set „Yes‟. The signal connected to this input has been lost. Posible cause: Analogue input cable has come loose or disconnected (T12 and T13). Actions: Verify the wiring and the device, which provides the analogue signal. If the fault persists, change Control PCB. Fault: F44 CAL FLT Descrtiption: Internal reference voltage levels are wrong. Posible cause: SD700 fault. Actions: Verify drive select. Replace the drive select Fault: F45 STOP T/O Descrtiption: Trip generated due to excessive stopping time. The elapsed time from stop signal activation has exceeded the value set in parameter „G11.2 STOP TO‟. Posible cause: Deceleration ramps (parameters „G5.2 DECEL1‟ and „G5.4 DECEL2‟) are too slow; SD700 is limiting voltage due to the regeneration of the motor. Actions: Verify that the time set in parameter „G11.2 STOP TO‟ to stop the system after setting deceleration ramps and checking the system performance. SERVICE MANUAL 17 SD700 POWER ELECTRONICS Fault: F46 EEPROM FLT Descrtiption: Trip generated due to excessive stopping time. The elapsed time from stop signal activation has exceeded the value set in parameter „G11.2 STOP TO‟. Posible cause: Integrated circuit fault. Actions: Change the Control PCB Fault: F47 COMMS T/O Descrtiption: Trip generated due to excessive delay of serial communication. The elapsed time from the last valid data transmission has exceeded the time set in parameter „G20.2 COMMS T/O‟. Posible cause: Communications cable has come loose or cut; Master device has not sent valid data in the required frame or it has sent incorrect data. Actions: Verify the wiring of communications system; verify the data and settings of the master device. If the fault persists, change the Control PCB Fault: F48 SPI COM Descrtiption: Trip due to a wrong data bus transfer. Posible cause: Input power fault. Actions: Reset the device and if the fault persists, change the Control PCB Fault: F49 SPD LIMIT Descrtiption: Motor speed has exceeded the speed limit (parameters G10.1 to G10.4) for the time set in „G11.1 SP LIM TO‟. Posible cause: Speed reference is higher than the speed limit; Motor speed is out of control or motor is accelerating because of the load. Actions: Verify speed limits. Fault: F50 PSU FAULT Descrtiption: Internal power supply is not supplying the correct voltage. The voltage level has dropped to zero value for 100ms approx. Posible cause: Damaged power supply. Actions: Reset the device and if the fault persists ask for technical assistance. Fault: F51 SCR TEMP Descrtiption: Rectifier heat sink temperature has reached a dangerous level. Posible cause: Temperature limits for SD700 rectifier has been exceeded. Actions: Verify that the ambient conditions are the proper ones for the device. Be sure that there is nothing obstructing the cooling fans (dust, papers, dirt, etc) and that these rotate correctly. In frame 6, 7 and 8, check that the current is the same in each rectifier. 18 SERVICE MANUAL SD700 POWER ELECTRONICS Fault: F52 SOFT C TEMP Descrtiption: A fault in the Fan power supply unit occurred. Posible cause: The fans of the device are operating wrongly; The Fan power supply unit is overheated. Actions: Verify that fans are not obstructed. Check that fans are not dirty and rotate correctly; Wait for the temperature of the power supply to go down to a normal value and restart it. You can disconnect the device, connect it again, and restart the power supply again. If the fault persists check the fan power supply fuses. Fault: F53 INTRNAL TEMP Descrtiption: Internal temperature of the SD700 control electronics chamber has reached a dangerous level. Posible cause: The limit of internal temperature of the electronics chamber has been exceeded. Actions: Verify that the ambient conditions are proper for the equipment. Be sure that there is nothing obstructing the cooling fans (dust, papers, dirt in general) and that these rotate correctly. If the fault persists change fans. Fault: F54 WATCHDOG TMR Descrtiption: Internal fault of the microcontroller. Posible cause: A fault in the microcontroller occurred. Actions: Disconnect and re-connect the input power of the drive. If the fault persists, change Control PCB. Fault: F56 EMERGEN.STOP Descrtiption: Digital input configured as „EXTERN EMERGE‟ has been activated (NC contact). Posible cause: An external trip occurred by closing a contact in the digital input configured in this option. Actions: Verify the wiring of digital input. Check the installation. Fault: F65 LOW PRESSURE Descrtiption: Active only when operating in Pump Control mode. Trip generated when the pressure level is lower than the minimum pressure level set in „G25.6.7 LoPre‟. Posible cause: Pressure reference is lower than the minimum pressure level (Active in Pump Control mode only). Actions: Verify the setting of minimum pressure level; Check the operation of the low pressure switch detector; Check the status of the analogue inputs 1 and 2 in parameters SV3.1 and SV3.4 in displaying group G0. Fault: F66 HI PRESSURE Descrtiption: Active only when operating in Pump Control mode. External trip occurred when a digital input is configured in this option (Hi Pressure Switch) is closed. SERVICE MANUAL 19 SD700 POWER ELECTRONICS Posible cause: An external trip occurred by closing a contact in the digital input configured in this option (Active in Pump Control mode only). Actions: Check if the pressure of the installation exceeds the set limits; Verify the wiring of digital input. Fault: F67 LOW WATER Descrtiption: An external trip occurred when the Pump Program (G25) is activated and one of the digital inputs has been set as ‟59 LO WATER FLT‟. Under these conditions, if a contact is opened in such digital input, the drive trips indicating that the pump is working with no load. Posible cause: An external trip occurred by opening a contact in the digital input. (Active in Pump Control mode only) Actions: A contact has been activated to indicate that there is a fault due to lack of water. Verify the conditions of the installation. Verify the wiring of digital input. Fault: F68 CAVIT/UNDERL Descrtiption: When the motor current is lower than the cavitation current and the motor speed is higher or equal than the cavitation speed during the time set for that purpose, the drive will trip. This avoids that the pump operates with no water (detection is done due to underload). Posible cause: Settings of the drive in protections group G25.6 are incorrect. Actions: Check if the pump of the installation is operating withoug water. Verify the settings of the parameters referred to the cavitation protection depending on the installation Fault: F69 FLOW SWITCH Description: The digital input configured as flow detection indicates flow absence according to the parameters set. See the protections set in G25.6 to obtain more detailed information. Possible cause: The pump is operating with no load; Setting protections in group G25.6 are wrong. Actions: Check if the pump of the installation is operating without water; verify the settings of the parameters referred to the cavitation protection depending on the installation. Fault: F70 IRRIGATOR F Description: The digital input configured as ‟62 IRRIGAT TRIP‟ detects that an external fault in the drive occurred. Possible cause: An external trip occurred due to the closure of a ontact in the digital input configured as IRRIGAT TRIP. Actions: Verify your irrigating equipment and check if the connections between the drive and the irrigating equipment are correct. 20 SERVICE MANUAL SD700 POWER ELECTRONICS Fault: F71 CYCLING Description: Conditions set in group G25.6 are not met compared to the cycle time of the drive and the cycle counter. The SD700 has started a higher number of times than the allowed number without softening the time set. Possible cause: The drive shows several start / stop cycles (wake up / sleep) in a short time. Actions: Verify possible leakages in the installation; verify the settings of this protection in group G25.6. Fault: F72 IN PRES SW Description: This fault ocurrs mainly due to two causes: 1. After starting the system, the time set in G25.9.11 has been exceeded without the digital input configured as PRESSUR SWITC being activated. 2. 2. After the priming pump has stopped and the drive pump has started, the digital input configured as PRESSUR SWITC is opened during the time set in G25.9.10. Possible cause: Breakage or low water in aspiration circuit. Actions: Verify the water level in the aspiration circuit (well, tank, etc.); Verify the status of the pressure switch. SERVICE MANUAL 21 SD700 POWER ELECTRONICS 4.3. Display fault YES ¿The Display ON? Look for the solution failure Change Control PCB NO ¿OK? (Section 4.2) NO ¿There is input voltage? NO YES ¿Led DC BUS ON? NO YES NO Failure Power PCB supply power YES Change Power PCB Change Power PCB NO NO NO Verify instalation ¿Input fuses OK? (Section 4.4.1) ¿Leds Power PCB OK? (Section 4.51) Change DIsplay YES YES ¿OK? YES ¿There is voltage inBus? (Section 4.3) YES ¿Power PCB YES fuses OK? (Section 4.4.2) NO Change Power PCB Fuses Figure 1.2. Display Fault 22 SERVICE MANUAL Change Power PCB NO ¿OK? SD700 POWER ELECTRONICS 4.4. Fuses fault The SDrive700 contains a certain number of fuses for safety reasons. The failure of a fuse is not a normal event, and is usually an indicative of further and more serious faults. For this reason fuses failure should be investigated. Most of the auxiliary fuses are located in the SDrive PCB. A list of fuses, with their locations, possible reasons for failure and suggested corrective actions, follows. 4.4.1. Supply fuses Function: Protect mains Place: In the 3 SD700 input phases. Possible reason for failure: Supply surge; Age or cyclic stress failure; wrong fuses; fault in supply cable; rectifier or inverter fault. Action: Take out the covers and make a visual inspection. Check that there is no fire or a blast sign. Check the SD700 and follow figure 1.3 instructions to verify that any short circuit occurredt. Each test is carried out 3 times (i.e. once per phase), which makes a total of 12 test. Figure 1.3. Display Fault SERVICE MANUAL 23 SD700 POWER ELECTRONICS 4.4.2 Fuses Frame 1 a) Fuses of the Power Board In the power board, there are 2 fuses located where the figure 1.4 shows. FUSE 1 FUSE 2 Figure 1.4 Fuses of the power board Fuse 1 and Fuse 2: Function: protection for the fast charge circuits of the bus on power board. Value of 4 A. Possible reason for failure: Fuse fault or faulty circuit. Action: Replace the fuse or the board. 24 SERVICE MANUAL SD700 POWER ELECTRONICS b) Fuses of the Power Connection Board In the power connection board, there are 3 fuses located where the figure 1.5 shows. FUSE 1 FUSE 2 FUSE 3 Figure 1.5. Fuses of the power connection board Fuse 1, Fuse 2 and Fuse 3: Function: Protection for input voltage measurement circuit before the chokes. Value of 2 A. Possible reason for failure: Fuse fault or faulty circuit. Action: Replace the fuse or the board. SERVICE MANUAL 25 SD700 POWER ELECTRONICS 4.4.3. Fuses Frame 2 a) Fuses of the Power Board In the power board, there are 2 fuses located where the figure 1.4 shows. FUSE 1 FUSE 2 Figure 1.4 Fuses of the power board Fuse 1 and Fuse 2: Function: protection for the fast charge circuits of the bus on power board. Value of 4 A. Possible reason for failure: Fuse fault or faulty circuit. Action: Replace the fuse or the board. 26 SERVICE MANUAL SD700 POWER ELECTRONICS b) Fuses of the Power Connection Board In the power connection board, there are 3 fuses located where the figure 1.5 shows. FUSE 1 FUSE 2 FUSE 3 Figure 1.5. Fuses of the power connection board Fuse 1, Fuse 2 and Fuse 3: Function: Protection for input voltage measurement circuit before the chokes. Value of 2 A. Possible reason for failure: Fuse fault or faulty circuit. Action: Replace the fuse or the board. SERVICE MANUAL 27 SD700 POWER ELECTRONICS 4.4.3 Fuses Frame 3 (60 – 75A) a) Fuses of the Power Board In the power board, there are 6 fuses located where the figure 1.4 shows. FUSE 4 FUSE 1 FUSE 5 FUSE 2 FUSE 6 FUSE 3 Figure 1.4 Fuses of the power board Fuse 1 and Fuse 2: Characteristics: They are very fast-acting ceramic fuses. Their value is 4 A. Function: Power supply for the power board from its bus. Possible reason for failure: Internal short-circuit in the power board. Action: Replace the power board. Fuse 3: Characteristics: glass tube fuse. The value is 100 mA. Function: It discharges the bus of the drive. Possible reason for failure: Faulty circuit and bus always discharging. Action: Replace the power board. Fuse 4, Fuse 5 and Fuse 6: Function: protection for input voltage measurement circuit before chokes and detection of input voltage to avoid the discharge of the bus. The value is 2 A. 28 SERVICE MANUAL SD700 POWER ELECTRONICS Possible reason for failure: Circuit fault or faulty fuse. Action: Replace the fuse or the board. b) Fuses of the Power Connection Board In the power connection board, there are 3 fuses located where the figure 1.5 shows. FUSE 1 FUSE 2 FUSE 3 Figure 1.5. Fuses of the power connection board Fuse 1, Fuse 2 and Fuse 3: Function: Protection for soft-load circuits. The value is 4 A. Possible reason for failure: Fuse fault or faulty circuit. Action: Replace the fuse or the board. SERVICE MANUAL 29 SD700 POWER ELECTRONICS 4.4.4 Fuses Frame 3 (90 -115A) a) Fuses of the Power Board In the power board, there are 6 fuses located where the figure 1.4 shows. FUSE 4 FUSE 1 FUSE 5 FUSE 2 FUSE 6 FUSE 3 Figure 1.4 Fuses of the power board Fuse 1 and Fuse 2: Characteristics: They are very fast-acting ceramic fuses. Their value is 4 A. Function: Power supply for the power board from its bus. Possible reason for failure: Internal short-circuit in the power board. Action: Replace the power board. Fuse 3: Characteristics: glass tube fuse. The value is 100 mA. Function: It discharges the bus of the drive. Possible reason for failure: Faulty circuit and bus always discharging. Action: Replace the power board. 30 SERVICE MANUAL SD700 POWER ELECTRONICS Fuse 4, Fuse 5 and Fuse 6: Function: protection for input voltage measurement circuit before chokes and detection of input voltage to avoid the discharge of the bus. The value is 2 A. Possible reason for failure: Circuit fault or faulty fuse. Action: Replace the fuse or the board. b) Fuses of the Power Connection Board In the power connection board, there are 3 fuses located where the figure 1.5 shows. FUSE 1 FUSE 2 FUSE 3 Figure 1.5. Fuses of the power connection board Fuse 1, Fuse 2 and Fuse 3: Function: Protection for soft-load circuits. The value is 4 A. Possible reason for failure: Fuse fault or faulty circuit. Action: Replace the fuse or the board. SERVICE MANUAL 31 SD700 POWER ELECTRONICS 4.4.5 Fuses Frame 4 - Frame 11 (400VAC) a) Fuses of the Power Board There are 4 fuses in the Power PCB, as it is showed in figure 1.4: FUSE 4 FUSE 3 FUSE 1 FUSE 2 Figure 1.4. Power PCB fuses Fuse 1 and Fuse 2: Characteristics: These are ultrarrapid ceramic fuses. These fuses are 4A Function: Power supply PCB from the Power PCB‟s Bus. Possible reason for failure: Short circuit in the Power PCB Action: Change the Power PCB. Fuse 3: Characteristics: These are ultrarrapid ceramic fuses. Its value is 4A Function: DC Bus Discharge. Possible reason for failure: Circuit damaged and DC Bus always discharged. Action: Change the Power PCB. Fuse 4: Características: Glass fuse. This is a 2A fuse. Function: 15V_IGBT supply 32 SERVICE MANUAL SD700 POWER ELECTRONICS Possible reason for failure: IGBT damaged. Action: Check IGBTs (Section 6.4) b) Snubber PCB FRAME 4 Figure 1.5. Frame 4 Snubber PCB fuses FRAME 5,6,7,8 Figure 1.6. Frame 5,6,7,8 Snubber PCB fuses Fuse 1A, 2A, 3A: Characteristics: These are ultrarrapid ceramic fuses. These fuses are 4A Function: 1) Soft circuit charge protection, 2) Protection of the input voltage measure circuit after the AC choke Possible reason for failure: Short circuit in the Power PCB Action: Change the Power PCB. Fuse 1B, 2B, 3B: SERVICE MANUAL 33 SD700 POWER ELECTRONICS Characteristics: These are ultrarrapid ceramic fuses. Their value depends on the device Function: Protection of the input voltage measure circuit before the AC choke Possible reason for failure: Short circuit in the Power PCB Action: Change the Power PCB. c) Fans Power Supply. There are 3 fuses with the same function: Function: Fan‟s power supply protection Possible reason for failure: Short circuit in the fans power supply Action: Change the fans power supply. Figure 1.7. Fans power supply fuses 34 SERVICE MANUAL SD700 POWER ELECTRONICS 4.5 Indicator Leds 4.5.1 Indicator Leds Frame 1 a) Indicator Leds of Power Board The PCB‟s of the SD700 drives have several leds which report us about the operation of the drive, and can give us the information about the component that operates wrongly. - D114: RED colour. In normal operation, it is always ON. It indicates that DC Bus is charged. When it is OFF, the Bus is completely discharged. - D507: RED colour. In normal operation, it is always OFF. It is blinking if there is a fault in the main power supply. This fault can be: - High Bus voltage - Low Bus voltage; - High internal temperature of the drive; - Short-circuit in the main power supply of the power board. - D103: RED colour. In normal operation it is always ON. It indicates that the bus of the power board is powered. - D212: RED colour. In normal operation it is always ON. It indicates +24V Fans OK. - D216: RED colour. In normal operation it is always ON. It indicates +28V Display Power. - D214: RED colour. In normal operation it is always ON. It indicates +24V User. - D213: RED colour. In normal operation it is always ON. It indicates +24V Control. - D215: RED colour. In normal operation it is always ON. It indicates +15V IGBT. - D307: RED colour. In normal operation it is always ON. It indicates +8V User. - D207: RED colour. In normal operation it is always ON. It indicates -15V Dynamic Brake. - D204: RED colour. In normal operation it is always ON. It indicates +15V Dynamic Brake. - LED1: GREEN colour. In normal operation it is always ON. It indicates detection from the IGBT thermal protection. SERVICE MANUAL 35 SD700 POWER ELECTRONICS b) Indicator Leds of Control Board Figure 1.7. Leds of Control Board LED 10: GREEN colour. In normal operation, it is blinking. It indicates that the microprocessor is operating correctly. LED 901: GREEN colour. In normal operation it is always ON. It indicates that the power supply for the DSP (3,3V) is correct. LED 1101: GREEN colour. In normal operation, it is always OFF. It is lit if there is overheating in the integrated circuit for RS485 communications. LED 1201: RED colour. In normal operation, it is always OFF. It is lit when the Hardware current limitation is performing. 36 SERVICE MANUAL SD700 POWER ELECTRONICS c) Dc Bus Board Frame 1 - LED 1: RED colour. In normal operation it is always ON. It indicates that DC Bus is powered. - LED 2: RED colour. In normal operation, it is ON during the soft charge, and once the DC Bus is charge, the led becomes OFF. SERVICE MANUAL 37 SD700 POWER ELECTRONICS d) Gate Drive Board Frame 1 - - - - - - - - - case it becomes OFF. LED 8: YELLOW colour. In normal operation, it is always ON. It indicates +15V dynamic brake. LED 9: YELLOW colour. In normal operation, it is always ON. It indicates – 15V dynamic brake. NOTE: Leds L1, L2, L3, L4, L5, L6 and LED DB become OFF during 1s when saturation. 38 LED 1: RED colour. In normal operation, it is always ON. It indicates +15V IGBT FUSE. L1: GREEN colour. In normal operation, it is always ON. It indicates desaturation W +. L2: GREEN colour. In normal operation, it is always ON. It indicates desaturation W -. L3: GREEN colour. In normal operation, it is always ON. It indicates desaturation V +. L4: GREEN colour. In normal operation, it is always ON. It indicates desaturation V -. L5: GREEN colour. In normal operation, it is always ON. It indicates desaturation U +. L6: GREEN colour. In normal operation, it is always ON. It indicates desaturation U -. LED DB: GREEN colour. In normal operation, it is always ON. It indicates braking desaturation fault, in this SERVICE MANUAL SD700 POWER ELECTRONICS 4.5.2 Indicator Leds Frame 2 a) Indicator Leds of Power Board The PCB‟s of the SD700 drives have several leds which report us about the operation of the drive, and can give us the information about the component that operates wrongly. - D114: RED colour. In normal operation, it is always ON. It indicates that DC Bus is charged. When it is OFF, the Bus is completely discharged. - D507: RED colour. In normal operation, it is always OFF. It is blinking if there is a fault in the main power supply. This fault can be: - High Bus voltage - Low Bus voltage; - High internal temperature of the drive; - Short-circuit in the main power supply of the power board. - D103: RED colour. In normal operation it is always ON. It indicates that the bus of the power board is powered. - D212: RED colour. In normal operation it is always ON. It indicates +24V Fans OK. - D216: RED colour. In normal operation it is always ON. It indicates +28V Display Power. - D214: RED colour. In normal operation it is always ON. It indicates +24V User. - D213: RED colour. In normal operation it is always ON. It indicates +24V Control. - D215: RED colour. In normal operation it is always ON. It indicates +15V IGBT. - D307: RED colour. In normal operation it is always ON. It indicates +8V User. - D207: RED colour. In normal operation it is always ON. It indicates -15V Dynamic Brake. - D204: RED colour. In normal operation it is always ON. It indicates +15V Dynamic Brake. - LED1: GREEN colour. In normal operation it is always ON. It indicates detection from the IGBT thermal protection. SERVICE MANUAL 39 SD700 POWER ELECTRONICS b) Indicator Leds of Control Board Figure 1.7. Leds of Control Board LED 10: GREEN colour. In normal operation, it is blinking. It indicates that the microprocessor is operating correctly. LED 901: GREEN colour. In normal operation it is always ON. It indicates that the power supply for the DSP (3,3V) is correct. LED 1101: GREEN colour. In normal operation, it is always OFF. It is lit if there is overheating in the integrated circuit for RS485 communications. LED 1201: RED colour. In normal operation, it is always OFF. It is lit when the Hardware current limitation is performing. c) Power Connection Board - 40 SERVICE MANUAL LED1: RED colour. In normal operation, it is ON during the soft charge, and once the DC Bus is charge, the led becomes OFF. SD700 POWER ELECTRONICS d) Dc Bus Board Frame 2 LED 1: RED colour. In normal operation it is always ON. It indicates that DC Bus is powered. e) Gate Drive Board Frame 2 - - LED 1: RED colour. In normal operation, it is always ON. It indicates +15V IGBT FUSE. L1: GREEN colour. In normal operation, it is always ON. It indicates desaturation W +. L2: GREEN colour. In normal operation, it is always ON. It indicates desaturation W -. L3: GREEN colour. In normal operation, it is always ON. It indicates desaturation V +. L4: GREEN colour. In normal operation, it is always ON. It indicates desaturation V -. L5: GREEN colour. In normal operation, it is always ON. It indicates desaturation U +. L6: GREEN colour. In normal operation, it is always ON. It indicates desaturation U -. LED DB: GREEN colour. In normal operation, it is always ON. It indicates braking desaturation fault, in this case it becomes OFF. LED 8: YELLOW colour. In normal operation, it is always ON. It indicates +15V dynamic brake. LED 9: YELLOW colour. In normal operation, it is always ON. It indicates – 15V dynamic brake. NOTE: Leds L1, L2, L3, L4, L5, L6 and LED DB become OFF during 1s when saturation. SERVICE MANUAL 41 SD700 POWER ELECTRONICS 4.5.3 Indicator Leds Frame 3 (60-75A) a) Indicator Leds of Power Board The PCB‟s of the SD700 drives have several leds which report us about the operation of the drive, and can give us the information about the component that operates wrongly. D307 D230 LED 1 LED 2 LED 3 D114 D507 D1000 D103 D216 D262 D212 D214 D215 D213 Figure 1.6. Leds of the power board D114: RED colour. In normal operation, it is always ON. It indicates that DC Bus is charged. When it is OFF, the Bus is completely discharged. D507: RED colour. In normal operation, it is always OFF. It is blinking if there is a fault in the main power supply. This fault can be: - High Bus voltage. - Low Bus voltage. - High internal temperature of the drive. - Short-circuit in the main power supply of the power board. D1000: GREEN colour. In normal operation, it is always OFF. It is lit when the discharging circuit for the DC BUS is active. D307: RED colour. In normal operation, it is always ON. It indicates that the power supply +8V_USR is correct. If it is not lit, it indicates there are problems in the user power supply (+5V_USR and +5V_COM). D103: RED colour. In normal operation, it is always ON. It indicates that the internal Bus of the power board is charged. If it is not lit, the main power supply is not operating. 42 SERVICE MANUAL SD700 POWER ELECTRONICS D262: RED colour. In normal operation, it is always ON. It indicates that the power supply +28V_DISP_PWR is correct. If it is not lit, the Display is not powered. D216: RED colour. In normal operation, it is always ON. It indicates that the power supply +24V_DISP_COM is correct. If it is not lit, there is a communication fault between the Display and the Control Board. D212: RED colour. In normal operation, it is always ON. It indicates that the power supply +15V_SCR is correct. If it is not lit, it indicates there are problems in the triggering thyristor pulse generator circuit. D214: RED coloutr. In normal operation, it is always ON. It indicates that the power supply +28V_USR is correct. If it is not lit, all the voltages referred to the user ground dissapear. D215: RED colour. In normal operation, it is always ON. It indicates that the power supply +15V_IGBT is correct. If it is not lit, there are not pulses in the IGBT‟s. There is some faulty component in the inverter circuit (IGBTs, GateDrive…). D213: RED colour. In normal operation, it is always ON. It indicates that the power supply +24V_CONTROL is correct. If it is not lit, all the voltages referred to the analogue and digital ground dissapear. D230: RED colour. In normal opertion, it is always ON. It indicates that the power supply +15V_TEMP is correct. If it not lit, the temperature measurement faults. LED 1, LED2 AND LED 3: GREEN colour. It is only lit one of them, and corresponds to the output phase (IGBT‟s) with higher temperature. b) Indicator Leds of Control Board Figure 1.7. Leds of the Control Board LED 10: GREEN colour. In normal operation, it is blinking. It indicates that the microprocessor is operating correctly. LED 901: GREEN colour. In normal operation it is always ON. It indicates that the power supply for the DSP (3,3V) is correct. LED 1101: GREEN colour. In normal operation, it is always OFF. It is lit if there is overheating in the integrated circuit for RS485 communications. LED 1201: RED colour. In normal operation, it is always OFF. It is lit when the Hardware current limitation is performing. SERVICE MANUAL 43 SD700 POWER ELECTRONICS c) Indicator Leds of Dc Bus Board LED 1 LED 2 Figure 1.8. Leds of DC BUS LED 1: RED colour. In normal operation it is always ON. It indicates that DC Bus is powered. LED 2: RED colour. In normal operation, it is ON during the soft charge, and once the DC Bus is charge, the led becomes OFF. 44 SERVICE MANUAL SD700 POWER ELECTRONICS d) Indicator Leds of Pluggable Pcb of Trigger Thyristors D2 LED 1 LED 2 LED 3 Figure 1.9. Leds of pluggable PCB of trigger thyristors D2: RED colour. It reports us that the power supply for the triggering of the thyristors is correct (+5v_SCR). LED 1, LED 2 AND LED 3: GREEN colour. They report us that the triggerings of the thyristors are being correctly performed. SERVICE MANUAL 45 SD700 POWER ELECTRONICS e) Indicator Leds of the Upper Gate Drive Board LED 1 L1 L2 L3 L4 L5 L6 Figure 2.0. Upper gate drive board LED 1: RED colour. In normal operation, it is always ON. It indicates +15V IGBT FUSE. L1: GREEN colour. In normal operation, it is always ON. It indicates desaturation W +. L2: GREEN colour. In normal operation, it is always ON. It indicates desaturation W -. L3: GREEN colour. In normal operation, it is always ON. It indicates desaturation V +. L4: GREEN colour. In normal operation, it is always ON. It indicates desaturation V -. L5: GREEN colour. In normal operation, it is always ON. It indicates desaturation U +. L6: GREEN colour. In normal operation, it is always ON. It indicates desaturation U -. 46 SERVICE MANUAL SD700 POWER ELECTRONICS 4.5.4 Indicator Leds Frame 3 (90-115A) a) Indicator Leds of Power Board The PCB‟s of the SD700 drives have several leds which report us about the operation of the drive, and can give us the information about the component that operates wrongly. D307 D230 LED 1 LED 2 LED 3 D114 D507 D1000 D103 D216 D262 D212 D214 D215 D213 Figure 1.6. Leds of the power board D114: RED colour. In normal operation, it is always ON. It indicates that DC Bus is charged. When it is OFF, the Bus is completely discharged. D507: RED colour. In normal operation, it is always OFF. It is blinking if there is a fault in the main power supply. This fault can be: - High Bus voltage. - Low Bus voltage. - High internal temperature of the drive. - Short-circuit in the main power supply of the power board. D1000: GREEN colour. In normal operation, it is always OFF. It is lit when the discharging circuit for the DC BUS is active. D307: RED colour. In normal operation, it is always ON. It indicates that the power supply +8V_USR is correct. If it is not lit, it indicates there are problems in the user power supply (+5V_USR and +5V_COM). D103: RED colour. In normal operation, it is always ON. It indicates that the internal Bus of the power board is charged. If it is not lit, the main power supply is not operating. SERVICE MANUAL 47 SD700 POWER ELECTRONICS D262: RED colour. In normal operation, it is always ON. It indicates that the power supply +28V_DISP_PWR is correct. If it is not lit, the Display is not powered. D216: RED colour. In normal operation, it is always ON. It indicates that the power supply +24V_DISP_COM is correct. If it is not lit, there is a communication fault between the Display and the Control Board. D212: RED colour. In normal operation, it is always ON. It indicates that the power supply +15V_SCR is correct. If it is not lit, it indicates there are problems in the triggering thyristor pulse generator circuit. D214: RED coloutr. In normal operation, it is always ON. It indicates that the power supply +28V_USR is correct. If it is not lit, all the voltages referred to the user ground dissapear. D215: RED colour. In normal operation, it is always ON. It indicates that the power supply +15V_IGBT is correct. If it is not lit, there are not pulses in the IGBT‟s. There is some faulty component in the inverter circuit (IGBTs, GateDrive…). D213: RED colour. In normal operation, it is always ON. It indicates that the power supply +24V_CONTROL is correct. If it is not lit, all the voltages referred to the analogue and digital ground dissapear. D230: RED colour. In normal opertion, it is always ON. It indicates that the power supply +15V_TEMP is correct. If it not lit, the temperature measurement faults. LED 1, LED2 AND LED 3: GREEN colour. It is only lit one of them, and corresponds to the output phase (IGBT‟s) with higher temperature. 48 SERVICE MANUAL SD700 POWER ELECTRONICS c) Indicator Leds of Control Board Figure 1.7. Leds of the Control Board LED 10: GREEN colour. In normal operation, it is blinking. It indicates that the microprocessor is operating correctly. LED 901: GREEN colour. In normal operation it is always ON. It indicates that the power supply for the DSP (3,3V) is correct. LED 1101: GREEN colour. In normal operation, it is always OFF. It is lit if there is overheating in the integrated circuit for RS485 communications. LED 1201: RED colour. In normal operation, it is always OFF. It is lit when the Hardware current limitation is performing. d) Indicator Leds of Dc Bus Board LED 1 LED 2 Figure 1.8. Leds of DC BUS LED 1: RED colour. In normal operation it is always ON. It indicates that DC Bus is powered. LED 2: RED colour. In normal operation, it is ON during the soft charge, and once the DC Bus is charge, the led becomes OFF. SERVICE MANUAL 49 SD700 POWER ELECTRONICS e) Indicator Leds of Pluggable Pcb of Trigger Thyristors D2 LED 1 LED 2 LED 3 Figure 1.9. Leds of pluggable PCB of trigger thyristors D2: RED colour. It reports us that the power supply for the triggering of the thyristors is correct (+5v_SCR). LED 1, LED 2 AND LED 3: GREEN colour. They report us that the triggerings of the thyristors are being correctly performed. f) Indicator Leds of the Upper Gate Drive Board LED 1 L1 L2 L3 L4 L5 L6 Figure 2.0. Upper gate drive board 50 SERVICE MANUAL SD700 POWER ELECTRONICS LED 1: RED colour. In normal operation, it is always ON. It indicates +15V IGBT FUSE. L1: GREEN colour. In normal operation, it is always ON. It indicates desaturation W +. L2: GREEN colour. In normal operation, it is always ON. It indicates desaturation W -. L3: GREEN colour. In normal operation, it is always ON. It indicates desaturation V +. L4: GREEN colour. In normal operation, it is always ON. It indicates desaturation V -. L5: GREEN colour. In normal operation, it is always ON. It indicates desaturation U +. L6: GREEN colour. In normal operation, it is always ON. It indicates desaturation U -. SERVICE MANUAL 51 SD700 POWER ELECTRONICS 4.5.5 CB LED Indicators The PCBs contains a certain number of LEDs, to indicate the status of the SD700, and they can notify if one element is wrong. a) Power PCB - D114: RED colour. In normal operation always ON. It shows that the DC Bus is charged. When it is off that means that the bus is completerly discharged. - D507: RED colour. In normal operation always OFF. It flickers when detects some hardware fault. These faults are: o o o o DC Bus High voltage DC Bus Low voltage Hight temperature in SD700 Short circuit in Power PCB supply - D1000: Green colour. In normal operation always OFF. It switches ON when the DC Bus discharge circuit is in operation. - D311: RED colour. In normal operation always ON. It shows that +5V_SCR supply is OK. If it does not turn on, this is an indicative of problems in the pulse generation circuit for firing the thyristors. - D307: RED colour. In normal operation always ON. It shows that +8V_USR supply is OK. If ti does not turn on, this is an indicative of problems in the user supply (+5V_USR y +5V_COM). - D244: RED colour. In normal operation always ON. It shows that +24V_DISP_COM supply is OK. If it does not turn on, there might be a failure in the communication between the Display and the Control Board. - D212: RED colour. In normal operation always ON. It shows that +15V_SCR supply is OK. - D213: RED colour. In normal operation always ON. It shows that +24V_CONTROL supply is OK. If it does not turn on, all the voltages referred to an analogical and digital mass disappear. - D214: RED colour. In normal operation always ON. It shows that +28V_USR supply is OK. If it does not turn on, all the voltages referred to the user mass disappear - D215: RED colour. In normal operation always ON. It shows that +15V_IGBT supply is OK. If it does not turn on, there are no pulses in the IGBT‟s. Any component of the inverter circuit is failing (IGBT‟s, GateDrive…) - D216: RED colour. In normal operation always ON. It shows that +28V_DISP_PWR supply is OK. If it does not turn on, the Display is not being supplied. - D230: RED colour. In normal operation always ON. It shows that +15V_TEMP supply is OK. If it does not turn on, the temperature measure circuit is failing. - D103: RED colour. In normal operation always ON. It shows that Power PCB Bus is charged. If it does not turn on, the main power supply is not operating. - LED 1 - LED 2 GREEN colour. In normal operation only one out of three is on. It shows the highest temperature of the three output phase (IGBTs) - LED 3 52 SERVICE MANUAL SD700 POWER ELECTRONICS Figure 1.8. Power PCB Leds b) Control PCB - LED 10: GREEN colour. It FLICKERS during normal conditions. It shows that the processor is in normal operation. - LED 901: GREEN colour. During normal operation always OFF. It shows that DSP (3,3V) supply is OK. - LED 1101: GREEN colour. During normal operation always OFF. It switches ON when it detects am excessive temperature in 485 communications integrated circuit. - LED 1201: RED colour. During normal operation always OFF. It switches ON when the hardware current limit is on. Figure 1.9. Control PCB LEDs SERVICE MANUAL 53 SD700 POWER ELECTRONICS c) Upper Gate Drive (Upper Econodual Driver) GREEN colour. In normal operation always ON. They switch OFF when they detect an IGBT failure. Figure1.10. Upper Gate Drive LEDs. If the LEDs of all the IGBTs switch OFF,that means that the Power PCB 4 fuses have blown 54 SERVICE MANUAL SD700 POWER ELECTRONICS 5. CONNECTIONS. 5.1 Power PCB -DC BUS measure: it connects this pcb with one of the thyristors, where the voltage in the bus is measured -Rapid discharged resistor: It connects this PCB with the Snubber, Trigger and Soft charge protection board. - Measure of the input voltage before the AC chokes: It connects this PCB with the Snubber, Trigger and Soft charge protection board. - Measure of the input voltage after the AC chokes: It connects this PCB with the Snubber, Trigger and Soft charge protection board. - Trigger of the SCR: It connects this PCB wiith the Va Snubber, Trigger and Soft charge protection board. - Temperature of the SCR: It connects this PCB with the heatsink of the thyristor an with the Fan power supply unit. - NTC 1, NTC 2 , NTC 3: In frame frame 4 and 5, they connect this PCB with the IGBT‟s, while in other frames they connect this PCB with the NTC PCB (IGBT module selection) - Current measure: It connects this PCB with the Current Transformers. - Output voltage measure: It connects this PCB with the Output bars. SERVICE MANUAL 55 SD700 POWER ELECTRONICS - Connector IGBT modules selection: It connects this PCB with the NTC PCB‟s (IGBT selection modules). If there is only one PCB in the device, the cable will come out from module 1. If there are two NTC PCB‟s, the cables will come out from modules 2 and 3. If there are three PCB, a cable will come out from any single module. - External supply: This contactor allows an external supply of all devices, which are supplied from the Power PCB as well, when the drive is not operating. For instance, it will allow to visualize in the Display when the drive does not work. - J804: this must be bridged, so that the IGBT‟s can receive trigger pulses. - JUMPERS: By default only the even numbers are connected. In this case, the mass of the chassis are connecte in paralel with a capacitor, a resistor and a baristor. -JP106: It refers to the DGND, which corresponds to the analogical and digital masses. -JP200: It refers to the GND_USR, which corresponds to the user mass. -JP104: It refers to the GND_COM, , which corresponds to the Display mass supply. If all the pairs of even and odd jumpers are connected, the masses are driven to the chassis and are not connected. This is used to solve field noises 56 SERVICE MANUAL POWER ELECTRONICS SD700 5.2 Control Board - J907: Connection of the Encoder Expansion PCB. - J101 and J102: Connection of the Devicenet PCB. - J100: Connector for programming the microprocesor BOOTSTRAP. - J202: Connector for programming the DSP BOOTSTRAP - J200: Programming of the DSP through the JTAG. - J1201: Connection of the Dynamic Braking expansion PCB. - J906: Connection of the Analogue and Digital inputs Expansion PCB. - J1102: Connection of the Fiber Optics Expansion PCB. - JP1103: Jumper for 232 and 485 - JP1104: Jumper for USB. SERVICE MANUAL 57 SD700 POWER ELECTRONICS 6. TESTING 6.1 Testing the rectifier and inverter. Refer to figure 1.4 by using a multimeter, check the rectifier as the drawing indicates. NOTE: each test is carried out 3 times (i.e. once per phase) which makes a total of 12 test. Figure 2.1. Rectifier and inverter testing The components and the numbers per phase are shown below to assist in understanding what you are testing. 1) In order to test the rectifier components individually, remove the input fuses and test on the load side the fuses 2) In order to test the IGBTs individually requires the disassembly of the SD700. Figure 2.2 Frame 4 Figure 2.3 Frame 5 58 SERVICE MANUAL SD700 POWER ELECTRONICS Figure 2.4 Frame 6 Figure 2.5 Frame 7 Figure 2.8 Frame 8 SERVICE MANUAL 59 SD700 POWER ELECTRONICS 6.2 Individual SCR testing. When the SD700 is dissembled, the SCR can be tested individually as it is shown in figure 2.7 Figure 2.7. Individual SCR conduction test. 6.3 Testing the DC Bus Capacitor. A general test without disassembling the SD700 is recommended. Use a multimeter set in mode OHMS to test the capacitors between HVDC terminals + and -. At first the resistance should offer a low value, but afterwards, as the resistance will increase as the it is supplied voltage from the battery of the multitester (ensure the DC bus capacitors are fully discharged first). This charging period could take some time and it is better to ensure this procedure by testing a similar DC Bus capacitors in good conditions. It is necessary to apply the same load time to both DC Buses and then compare results. If there is a reasonable difference between both measurments, the replacement of the DC Bus will be necessary. In order to test the capacitors individually, the DC Bus capacitors must have been disassembled from the SD700 and afterwards must be disassembled. Every capacitor must be measured with a multimeter and all of them must be discharged. The tester must be set in mode OHMS. Then the positive of the tester must be conneted to the positive of the capacitor and repeat the operation with the negative. If the capacitor works properly, the resistance should start low and then increase as the capacitor is charged due to the voltage in the battery of the tester. 6.4 Individual IGBT test In order to test an IGBT the use of a static grounding wrist strap and being earthed is necessary. When the SD700 is disassembled, the IGBTs can be tested individually as it is shown in figure 2.8. 60 SERVICE MANUAL SD700 POWER ELECTRONICS Figure 2.8. IGBT testing 6.5 Soft Powering After Repair. Once all faulty components have been replaced and the SD700 has been dully reassembled, a SD700 softpowering test is highly recommended through the plug-in of an extgernal soft power supply unit called Variac. This power supply generates 600 Vdc. Connect the Variac to HVDC Bus terminals. Then, when the Variac is on, it is necessary to increase voltage little by little and check that LEDS of the Power Supply and the leds of the upper gater drive turn on. Connect the Display and verify that there are not faults and compare the voltage of “variac” Figure 2.9. Soft Power Supply Connections SERVICE MANUAL 61 SD700 POWER ELECTRONICS 6.6 Checking external inputs If the SD700 powers up correctly but fails to respond to external inputs, the following procedures will enable these inputs to be checked. Before checking the external inputs, we must configure the SD700 in local mode (Screen „G4.1 CNTROL MODE1). Figure 2.10 External inputs 6.6.1 Check the analogue inputs Analogue input 1 Jumper input 19 with input 11, and input 18 with input 10. In the screen SV.3 „ANLG IN1‟ or SV.3 „AIN1 Refr‟ , the value of the analogue input 1 has to be the highest one allowed. Analogue input 2 Jumper input 19 with input 13, and input 18 with input 12. In the screen SV.3 „ANLG IN2‟ or SV.3 „AIN2 Refr‟ , the value of the analogue input 2 has to be the highest one allowed 62 SERVICE MANUAL 6.6.2 Check digital inputs The screen SV.3 „Input DG‟ shows whether the Digital Inputs are activated or not, from DI1 to DI6 as it is shown in figure 2.11 y 2.12 . A “X” is Active ,and “O” is not active - Jumper terminal 1 with terminal 2, and verify that the digital input 1 is connected: Figure 2.11 Digital Input 1 active - Jumper terminal 1 with terminal 3, and verify that the digital input 1 is connected: Figure2.12 Digital Input 2 active Verify that all inputs are right. SD700 POWER ELECTRONICS 7.SUBASSEMBLY REPLACEMENT Make sure the SD700 is safe to work, see section 3 before proceeding. 7.1. SD700 FRAME 1. 7.1.1. 4) ACCESS TO THE INSIDE OF THE DRIVE. Remove the 3 Phillips M4x8 DIN-7895H screws, with their corresponding whasers and grover whasers, which join the embellisher and the chassis (See figure 7.1.1 a) Disassembly of the embellishers In order to repair or replace any component of the drive, you should access to the inside of it. See figure 7.1.1 and figure 7.1.2 while reading the following instructions: 1) Remove the drive‟s door by unscrewing the 4 M4x8 DIN-7895H screws which fix it the the chassis. 2) Disconnect the Display. For this, disconnect ethernet cable which joins the display and the drive. Push the tab of the RJ45 connector and pull it up. 3) Disconnect all cables from the control terminals of the drive (analogue inputs and outputs, digital inputs and outputs, PTC input …). Figure 7.1.1 a 5) Disconnect the power supply cables of the fans in the embellishers. 6) Remove the embellishers. Figure 7.1.2 Access to the inside of the drive Figure 3.1 Display connection and control terminals Assembly of the embellishers 1) 64 SERVICE MANUAL Place the embellishers on the supports of the drive´s sides as the figure 7.1.1a shows. SD700 POWER ELECTRONICS 2) 3) 4) Screw the embellishers to the supports of the sides with 3 Phillips M4x8 DIN-7895H screws. Connect all cables from the control terminals of the drive (analogue inputs and outputs, digital inputs and outputs, PTC input …). Connect the Display by means of the ethernet cable which goes from the display to the drive. 7.1.2. DOOR Disassembly of the door See the figure 7.1.3 while following the next instructions: 1) Remove the door by unscrewing 4 Phillips M4x8 DIN-7895H screws. 2) Disconnect the ethernet cable from the display. 3) Remove the display from the support of the door. 4) Remove the door. Figure 7.1.3 Remove the door Assembly of the door 1) Put the display on the support of the door. 2) Connect the ethernet cable of the display. 3) Approach the door and fix it with the 4 Phillips M4x8 DIN-7895H screws. SERVICE MANUAL 65 SD700 POWER ELECTRONICS 7.1.3. UPPER COVERS. AND LOWER 7.1.4. CONTROL BOARD Disassembly of the control board Disassembly of the upper and lower covers 1) Unscrew the 8 Phillips M4x8 DIN-7895H screws that join the upper covers and the drive chassis (see figure 7.1.4). 2) Unscrew the 8 Phillips M4x8 DIN-7895H screws which join the lower covers and the drive chassis (see figure 7.1.5) 3) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. See the figure 7.1.6 while reading the following instructions: 1) Unscrew the 6 plastic screws M3x8 DIN933, which join the control board and the plastic hexagonal spacers M3x20. 2) Remove the control board by pulling it up, until disconnecting the female connectors of 40, 32 and 28 pins of the control board, from the male connectors of the power board where control board is connected. 3) Once the control board is removed, put this board into a static proof bag for a safekeeping. Remove the upper and lower covers. Figura 7.1.4 Figura 7.1.5 Assembly of the upper and lower covers 1) Screw the lower covers to the drive chassis with the 8 Phillips M4x8 DIN-7895H screws. 2) Screw the upper covers to the drive chassis with the 8 Phillips M4x8 DIN-7895H screws. Figure 7.1.6 Remove the control board 66 SERVICE MANUAL SD700 POWER ELECTRONICS Assembly of the control board 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the control board, avoid an excessive handling of the board. 3) Pick the new control board from the static proof bag. 4) Put the new control board in the same place than the replaced one, matching the board holes with the hexagonal plastic spacers M3x20 (see figure 7.1.6). 5) Match the male connector of 40, 32 and 28 pins of the control board with the corresponding female connector of the power board and slightly push the control board down to connect the pins. 6) Once the board is properly placed, screw the 6 plastic screws M3x8 DIN-933 in the corresponding hexagonal plastic spacers M3x20. 7.1.5. POWER BOARD Disassembly of the Power Board Before proceeding, the control board must have been disassembled (see section 7.1.4). See the figure 7.1.7 while reading the following instructions: 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect all the wires connected to this board. which are Figure 7.1.7. Disconnect all connected wires from power board 3) Remove the 6 hexagonal plastic spacers M3x20, which are joined to the electronic tray, and support the control board. 4) Unscrew the 5 Phillips screws M3x8 DIN7895H. 5) Remove the power board of the drive. Assembly of the power board 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the power board, avoid an excessive handling of the board. 3) Pick the new power board from the static proof bag. 4) Put the new power board in the same place than the replaced one. 5) Put the board on the electronic tray, matching the bolts of the tray with the holes of the board (see figure 7.1.8). SERVICE MANUAL 67 SD700 POWER ELECTRONICS 7.1.6. 6) Once the board is properly placed, screw the 5 Phillips screws M3x8 DIN-7895H in the bolts of the electronic tray. 7) Connect the cables to the corresponding connectors (see figure 7.1.7). 8) Put the hexagonal plastic spacers M3x20, screwing them in their corresponding bolts of the electronic tray, in order to place the control board later. DRIVE SELECT BOARD Disassembly of the Drive Select board Unscrew the 2 plastic screws M3x8 DIN-933, which join this board and the plastic hexagonal spacers M3x12. Figure 3.8a.Disassembly of the Drive Select board Assembly of the Drive Select board Put the drive select board on the 2 plastic hexagonal spacers M3x13 and join them with 2 plastic screws M3x8 DIN-933. Figure 7.1.8. Disassembly of the power board 68 SERVICE MANUAL SD700 POWER ELECTRONICS 7.1.7. GATE DRIVE BOARD 7.1.8. DC BUS Disassembly of Gate Drive board Disassembly of the DC Bus Before removing the gate drive board, it is necessary to remove the embellishers and the tray where control and power boards are inserted (see sections 7.1.1 – 7.1.4 – 7.1.15). Before proceeding, it is necessary to remove the embellishers (see section 7.1.1), the tray where control and power boards are inserted (see figure 7.1.7), the gate drive board (see section 7.1.7), the connections board (see section 7.1.9). See figure 7.1.9: 2) 3) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 1) Disconnect the braking cable, the bus cable, and the cable for connections of the gate drive board. Unscrew the 7 screws M3X6 DIN-7895H, which fix the bus board to the chassis (see figure 7.1.10) 2) Remove the 4 nuts M5 which fix the connections of the choke to the bus (see figure 7.1.1). 3) Remove the DC bus. Figure 7.1.9.Disassembly of the gate drive board 4) Unscrew the 3 Phillips screws M3x6 DIN7895H. 5) Remove the board. Figure 7.1.10 Assembly of Gate Drive board 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the gate drive board, avoid an excessive handling of the board. 3) Pick the new gate drive board from the static proof bag. 4) Figure 7.1.11 Assembly of the DC Bus 1) Put the bus matching the holes. Put the board in the correct position as the figure 7.1.9 shows, matching the holes. 2) Screw the 7 Phillips screws M3x6 DIN7895H that join the bus and the chassis. 5) Insert the 3 Phillips screws M3x6 DIN7895H. 3) Insert the 4 nuts M5 that join the choke and the bus board. 6) Connect the braking cable, the bus cable and the cable for connections of the gate drive board. SERVICE MANUAL 69 SD700 POWER ELECTRONICS 7.1.9. POWER CONNECTIONS BOARD 7.1.10. SINGLE-PHASE CHOKE Disassembly of the power connections board Disassembly of the single-phase choke Before removing the power connections board, you should remove the embellishers (see section 7.1.1), the tray wher the control and power boards are inserted (see figure 7.1.7) and the gate drive board (see section 7.1.17). In order to remove the single-phase choke, you should remove the embellishers (see section 7.1.1) and the tray for the boards (see figure 7.1.7) before. 1) 1) Disconnect the cables of the dV/dt coils, motor voltage measurement, cable for softload relay, cable for coil relay and NTC cable. 2) Remove the 2 screws of IGBT M5X16 DIN7895H (see figure 7.1.12). Unscrew the 4 screws M5X10 which join the bottom of the chassis and the top. See figure 7.1.14. Figure 7.1.14 2) Before separating the two chassis completely, disconnect the fan cable (see figure 7.1.15). Figure 7.1.12 3) Remove the 6 screws M3X6 (see figure 7.1.13) Figure 7.1.15 3) Remove the top of the chassis and put it face down (see figure 7.1.18). Figure 7.1.13 4) Remove the board. Assembly of the power connections board 1) Spread the heatsink area where the IGBT is going to be placed with new thermal paste. 2) Put the board in the proper position (see figure 7.1.13) 3) Screw the 2 IGBT screws M5X16 DIN7895H, with a tightening pressure of 5N/m. 4) Screw the 6 screws M3x6 that join the board and the chassis. 5) Connect all cables before described. 70 SERVICE MANUAL Figure 7.1.18 4) Disconnect the cables of the single-phase choke, by removing the screws M5X10 which joins them and the spacers (see figure 7.1.19). SD700 POWER ELECTRONICS 7.1.11. DV/DT CHOKES Disassembly of the dV/dt chokes Figure 7.1.19 5) Remove the 4 nuts M5 which fix the choke to the chassis. 6) Remove the choke. It is necessary to remove the embellishers (see section 7.1.1), the tray for the boards (see figure 7.1.7) and separate the top of the chassis from the bottom (follow the steps described in section 7.1.9 and 7.1.10) 1) Remove the 4 nuts M4 which fix dV/dt chokes to the chassis (see figure 7.1.20). Assembly of the single-phase choke 1) Fix the new single-phase choke to the chassis by using the nuts M5. 2) Connect the cables of the choke to the spacers (see figure 7.1.19). 3) Connect the cable for the fans. 4) Assembly again the top of the chassis with the bottom by means of the 4 screws M5X10 DIN-7895H. Figure 7.1.20 2) Disconnect all cables of the dV/dt choke from the connections board. 3) Remove dV/dt chokes. Assembly of the dV/dt chokes 1) Fix the new dV/dt chokes to the chassis by means of their nuts M4. 2) Put the cables of the new dV/dt choke through the holes of the chassis (see figure 7.1.21). Figure 7.1.21 3) Assembly again the top of the chassis with the bottom by means of the 4 screws M5X10 DIN-7895H. SERVICE MANUAL 71 SD700 POWER ELECTRONICS 7.1.12. HEATSINK 1.1.13 FANS Disassembly of the heatsink Disassembly of the heatsink fan In order to remove de heatsink, first, you should remove the embellishers (see section 7.1.1), the tray for the boards (see figure 7.1.7), the gate drive board (see section 7.1.7), the DC bus (see section 7.1.8) and the power connections board (see section 7.1.9), and separate the top of the chassis from the bottom (follow the steps of sections 7.1.9 and 7.1.10). 1) 1) Remove the lower cover (see section 7.1.3). 2) Disconnect the power supply cable. 3) Remove the 2 screws M4x45 DIN-84 that fix the fan to the structure (see figure 7.1.23). 4) Remove the fan. Remove the 4 screws M5X10 which fix the heatsink to the chassis of the drive (see figure 7.1.22). Figura 7.1.23 Assembly of the heatsink fan See figure 7.1.22 2) Remove the heatsink. Assembly of the heatsink 1) Fix the new heatsink to the chassis by using 4 screws M5x10, with a tightening pressure of 3N/m. 2) Join the top and the bottom of the chassis. 3) Spread the heatsink area where the IGBT of the power connections board is going to be placed, with thermal-conductor paste. 4) Fix the DC bus (see section 7.1.8) 5) Fix the power connections board (see section 7.1.19). 6) Fix the gate drive board (see section 7.1.7). 72 SERVICE MANUAL 1) Put the new fan and fix it with the screws. 2) Connect the power supply cable. 3) Fix the cover. SD700 POWER ELECTRONICS 7.2. SD700 FRAME 2. 7.2.1. ACCESS TO THE INSIDE OF THE DRIVE. Disassembly of the embellishers In order to repair or replace any component of the drive, you should access to the inside of it. See figure 7.2.1 and figure 7.2.2 while reading the following instructions: 1) Remove the drive‟s door by unscrewing the 4 M4x8 DIN-7895H screws which fix it the the chassis. 2) Disconnect the Display. For this, disconnect ethernet cable which joins the display and the drive. Push the tab of the RJ45 connector and pull it up. 3) Disconnect all cables from the control terminals of the drive (analogue inputs and outputs, digital inputs and outputs, PTC input …). Figure 7.2.1 a 5) In case of IP54 model of SD700 drives, disconnect the power supply of the fans that are in the embellishers. 6) Remove the support of the cover of the control board with the 2 screws M4x8 DIN7895H (see figure 7.2.1 b) Figure 7.2.1 b 7) Remove the embellishers. 8) Remove the plastic protector for the power connections. Figure 3.1 Display connection and control terminals 4) Remove the 4 Phillips M4x8 DIN-7895H screws, with their corresponding whasers and grover whasers, which join the lateral internal cover and the chassis (See figure 7.2.1 a). Figure 7.2.2 Access to the inside of the drive SERVICE MANUAL 73 SD700 POWER ELECTRONICS Assembly of the embellishers 1) 2) 3) 4) 5) Place the embellishers on the supports of the drive´s sides as the figures 7.2.1a and 7.2.1b show. Screw the embellishers to the supports of the sides with 6 Phillips M4x8 DIN-7895H screws. 7.2.2. Disassembly the door See the figure 7.2.3 while following the next instructions: 1) Remove the door by unscrewing 4 Phillips M4x8 DIN-7895H screws. 2) Disconnect the ethernet cable from the display. 3) Remove the display from the support of the door. 4) Remove the door. Put the plastic protector for the power connections on the sides of the drive. Connect all cables from the control terminals of the drive (analogue inputs and outputs, digital inputs and outputs, PTC input …). DOOR Connect the Display by means of the ethernet cable which goes from the display to the drive. Figure 7.2.3 Remove the door Assembly of the door 74 SERVICE MANUAL 1) Put the display on the support of the door. 2) Connect the ethernet cable of the display. 3) Approach the door and fix it with the 4 Phillips M4x8 DIN-7895H screws. SD700 POWER ELECTRONICS 7.2.3. UPPER COVERS. AND LOWER 7.2.4. CONTROL BOARD Disassembly of the control board Disassembly of the upper covers and the lower covers See the figure 7.2.4 while following the next instructions: 1) 2) Unscrew the 10 Phillips M4x8 DIN-7895H screws that join the upper covers and the drive chassis. In IP20 models, remove the upper cover slowly until disconnecting the power supply cable of the fans. Once disconnected the cable, remove the cover completely. 3) Unscrew the 8 Phillips M4x8 DIN-7895H screws which join the lower covers and the drive chassis. 4) Remove the upper and lower covers. The use of a static grounding wrist strap and being earthed is highly required to repair the unit. See the figure 7.2.5 while reading the following instructions: 1) Unscrew the 6 plastic screws M3x8 DIN933, which join the control board and the plastic hexagonal spacers M3x20. 2) Remove the control board by pulling it up, until disconnecting the female connectors of 40, 32 and 28 pins of the control board, from the male connectors of the power board where control board is connected. 3) Once the control board is removed, put this board into a static proof bag for a safekeeping. Figure 7.2.4 Remove the covers. Assembly of the upper covers and the and lower covers 1) Put the lower covers as the figure 3.4 shows. 2) Fix the covers to the chassis of the drive by using the 8 Phillips screws M4x8 DIN7895H that join the lower covers and the chassis. 3) Move the upper covers closer to the chassis of the drive, and connect the power supply cable of the fans. 4) Screw the upper covers to the drive chassis by using the 10 Phillips screws M4x8 DIN7895H. Figure 7.2.5 Remove the control board SERVICE MANUAL 75 SD700 POWER ELECTRONICS Assembly of the control board 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the control board, avoid an excessive handling of the board. 3) Pick the new control board from the static proof bag. 4) Put the new control board in the same place than the replaced one, matching the board holes with the hexagonal plastic spacers M3x20 (see figure 7.2.6). 5) Match the male connector of 40, 32 and 28 pins of the control board with the corresponding female connector of the power board and slightly push the control board down to connect the pins. 6) Once the board is properly placed, screw the 6 plastic screws M3x8 DIN-933 in the corresponding hexagonal plastic spacers M3x20. 7.2.5. POWER BOARD Disassembly of the power board Before proceeding, the control board must have been disassembled (see section 7.2.4). See the figure 7.2.6 while reading the following instructions: 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect all the wires connected to this board. which are Figure 7.2.6. Disconnect all connected wires from power board 3) Remove the 6 hexagonal plastic spacers M3x20, which are joined to the electronic tray, and support the control board. 4) Unscrew the 5 Phillips screws M3x8 DIN7895H. 5) Remove the power board of the drive. Assembly of the power board 76 SERVICE MANUAL 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the power board, avoid an excessive handling of the board. 3) Pick the new power board from the static proof bag. 4) Put the new power board in the same place than the replaced one. 5) Put the board on the electronic tray, matching the bolts of the tray with the holes of the board (see figure 7.2.7) SD700 POWER ELECTRONICS 7.2.6. 6) Once the board is properly placed, screw the 5 Phillips screws M3x8 DIN-7895H in the bolts of the electronic tray. 7) Connect the cables to the corresponding connectors (see figure 7.2.6). 8) Put the hexagonal plastic spacers M3x20, screwing them in their corresponding bolts of the electronic tray, in order to place the control board later. DRIVE SELECT BOARD Disassembly of the Drive Select board Unscrew the 2 plastic screws M3x8 DIN-933, which join this board and the plastic hexagonal spacers M3x12. Figure 7.2.8. Disassembly of the Drive Select board Assembly of the Drive Select board Put the drive select board on the 2 plastic hexagonal spacers M3x13 and join them with 2 plastic screws M3x8 DIN-933. Figure 7.2.7. Disassembly of the power board SERVICE MANUAL 77 SD700 POWER ELECTRONICS 7.2.7. GATE DRIVE BOARD 7.2.8. DC BUS Disassembly of the Gate Drive board Disassembly of DC Bus Before removing the gate drive board, it is necessary to remove the embellishers and the tray where control and power boards are inserted (see sections 7.2.1 – 7.2.4 – 7.2.15). Before proceeding, it is necessary to remove the embellishers (see section 7.2.1) and the tray where the control and power board are inserted (see figure 7.2.7). See figure 7.2.9: 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect the braking cable, the bus cable, and the cable for connections of the gate drive board. 1) Unscrew the 2 screws (M5X10 DIN-7895H), which fix the bus board with the power connections board. 2) Unscrew the 3 Phillips screws M3x8 DIN7895H which join the bus and the chassis. See figure 7.2.12. 3) Remove the DC bus. Figure 7.2.9.Disassembly of the gate drive board 3) Unscrew the 4 Phillips screws M3x8 DIN-7895H. Figure 7.2.12. Disassembly of DC Bus 4) Remove the board. Assembly of the Gate Drive board 1) 78 Continue with the safety conditions which are described in the previous section. 2) While replacing the gate drive board, avoid an excessive handling of the board. 3) Pick the new gate drive board from the static proof bag. 4) Put the board in the correct position as the figure 7.2.9 shows, matching the holes. 5) Insert the 4 Phillips screws M3x8 DIN7895H. 6) Connect the braking cable, the bus cable and the cable for connections of the gate drive board. SERVICE MANUAL Assembly of DC Bus 1) Put the bus matching the holes. 2) Screw the 3 Phillips screws M3x8 DIN7895H which join the bus and the chassis. 3) Screw the 2 screws (M5X10 DIN-7895H) which join the connections board with the DC Bus. SD700 POWER ELECTRONICS 7.2.9. POWER CONNECTIONS BOARD 3) Screw the 4 IGBT screws M5X16 DIN7895H, with a tightening pressure of 5N/m. Disassembly of the power connections board 4) Fix the 6 nuts M5 that join the fan structure and the connections board. 5) Insert the 2 plastic screws M3x8 DIN-933. 6) Insert the Phillips screw M3x8 DIN-7895H of the chassis. 7) Connect the NTC cable. Before removing the power connections board, you should remove the embellishers (see section 7.2.1), the tray where the control and power boards are inserted (see figure 7.2.7), the DC Bus (see section 7.2.9) and the gate drive board (see section 7.2.7). 1) Disconnect the NTC cable. 2) Remove the 4 screws of IGBT M5X16 DIN7895H (see figure 7.2.13). 3) Remove the 6 nuts M5 that join the fan strucutre and the connections board (see figure 7.2.14). 4) Remove the Phillips screw M3x8 DIN7895H of the chassis. 5) Remove the 2 plastic screws M3x8 DIN933. 6) Remove the board. Figure 7.2.13. Disassembly of the power connections board Figure 7.2.14 Assembly of the power connections board 1) Spread the heatsink area where the IGBT is going to be placed with new thermal paste. 2) Put the board in the proper position (see figure 7.2.13). SERVICE MANUAL 79 SD700 POWER ELECTRONICS 7.2.10. SINGLE-PHASE CHOKES Assembly of the single-phase chokes 1) Fix the new single-phase chokes to the chassis by using the nuts M5. 2) Take the cables of the chokes toward the top of the chassis (see figure 7.2.18). Disassembly of the single-phase chokes In order to remove the single-phase choke, you should remove the embellishers (see section 7.2.1) and the tray for the boards (see figure 7.2.7) before. 1) It is necessary to disconnect the power cables in order to remove the single-phase chokes from the chassis of the drive. For this, disconnect the power cables which are connected to the power connections board (see figure 7.2.17). 2) Remove the 6 nuts M5 which join the fan structure and the power connections board (see figure 7.2.14). Figure 7.2.17 3) Remove the 4 screws M6X16 DIN-7895H which join the upper chassis and the lower chassis. 4) Remove the top of the chassis and put it face down (see figure 7.2.18). Figure 7.2.18 5) Remove the 8 nuts M5 which fix the chokes to the chassis. 6) Remove the chokes. 80 SERVICE MANUAL Figure 7.2.18 3) Connect the cables of the chokes to the power connections board (see figure 7.2.17). 4) Approach and fix the fan structure to the power connetions board by using the 6 nuts M5. 5) Assembly again the top of the chassis qith the bottom of the chassis by using the 4 screws M6X16 DIN-7895H. SD700 POWER ELECTRONICS 7.2.11. DV/DT CHOKES Disassembly of dV/dt chokes It is necessary to remove the embellishers (see section 7.2.1), the tray for the boards (see figure 7.2.7) and separate the top of the chassis from the bottom (follow the steps described in section 7.2.9 and 7.2.10) Follow the steps while seeing the figure 7.2.19. Figure 7.2.20 4) Once disconnected the cables, cut the terminals in order to get the cables out the structure (see figure 7.2.21). Figure 7.2.21 Figure 7.2.19 1) 2) Remove the 4 screws (M4x8 DIN-7895H) which fix dV/dt chokes to the chassis (see figure 7.2.22). 5) Assembly dV/dt chokes 1) Put the cables of the new dV/dt choke through the holes of the fan structure (see figure 7.2.21). 2) Put the terminals of the ne dV/dt choke and connect them to the fan structure (see figures 7.2.23 and 7.2.20). Remove the 4 screws (M4x8 DIN-7895H) which join the fan structure to the chassis (see figure 7.2.22). Figure 7.2.22 3) Disconnect all the cables of dV/dt choke which are joined to the fan structure (see figure 7.2.20). Remove dV/dt chokes. Figure 7.2.23 3) Fix the fan structure to the chassis by using the 4 screws (M4x8 DIN-7895H). See figure 7.2.22. 4) Fix dV/dt chokes to the chassis by using the 4 screws (M4x8 DIN-7895H). See figure 7.2.22. 5) Assembly again the top and the bottom of the chassis. Follow the steps described in section 7.2.10 (see figure 7.2.18). SERVICE MANUAL 81 SD700 POWER ELECTRONICS 7.2.12. HEATSINK 1.1.13 FANS Disassembly of the heatsink Disassembly of the fan of the heatsink In order to remove de heatsink, first, you should remove the embellishers (see section 7.2.1), the tray for the boards (see figure 7.2.7), the gate drive board (see section 7.2.7), the DC bus (see section 7.2.8) and the power connections board (see section 7.2.9). 1) 2) Once removed the components mentioned before, remove the screws that join the upper chassis and the lower chassis (see figure 7.2.18). 1) Remove the lower cover (see section 7.2.3). 2) Disconnect the power supply cable. 3) Remove the 2 screws M4x45 DIN-84 that fix the fan to the structure (see figure 7.2.25). 4) Remove the fan. Remove the 4 screws M5X10 that fix the heasink to the chassis of the drive (see figure 7.2.24). Figure 7.2.25 Assembly of the fan of the heatsink 1) Put the new fan and fix it with the screws. See figure 7.2.24 2) Connect the power supply cable. 3) 3) Fix the cover. Remove the heatsink. Assembly of the heatsink 1) Fix the new heatsink to the chassis by using 4 screws M5x10, with a tightening pressure of 3N/m. Disassembly of the fan of the lateral internal cover 1) Remove the lateral internal cover (see section 7.2.1). 2) Join the top and the bottom of the chassis. 2) Disconnect the power supply cable. 3) Spread the heatsink area where the IGBT of the power connections board is going to be placed, with thermal-conductor paste. 3) Remove 2 screws M4x35 DIN-84 which join the fan and the chassis. See figure 7.2.26. 4) Fix the power connections board (see section 7.2.19). 4) Remove the fan. 5) Fix the DC bus (see section 7.2.8). 6) Fix the gate drive board (see section 7.2.7). Figure 7.2.26 82 SERVICE MANUAL POWER ELECTRONICS SD700 Assembly of the fan of the lateral internal cover 1) Put the new fan and fix it with the screws. 2) Connect the power supply cable. SERVICE MANUAL 83 SD700 POWER ELECTRONICS 7.3. SD700 FRAME 3 7) (60-75A) 7.3.1. Remove the plastic protector for the power connections. ACCESS TO THE INSIDE OF THE DRIVE. Disassembly of the embellishers In order to repair or replace any component of the drive, you should access to the inside of it. See figure 7.3.1 and figure 7.3.2 while reading the following instructions: 1) Open the door of the drive. 2) Disconnect the Display. For this, disconnect ethernet cable which joins the display and the drive. Push the tab of the RJ45 connector and pull it up. 3) Disconnect all cables from the control terminals of the drive (analogue inputs and outputs, digital inputs and outputs, PTC input …). Figure 7.3.2 Access to the inside of the drive Assembly of the embellishers Figure 7.3.1 Display connection and control terminals 4) Remove the 4 Phillips M4x8 DIN-7895H screws, with their corresponding whasers and grover whasers, which join the embellishers to the chassis of the drive. 5) In case of IP54 model of SD700 drives, disconnect the power supply of the fans that are in the embellishers. 6) Remove the embellishers. 84 SERVICE MANUAL 1) Place the embellishers on the supports of the drive´s sides as the figures 7.3.2 shows. 2) Screw the embellishers to the supports of the sides with 4 Phillips M4x8 DIN-7895H screws. 3) Put the plastic protector for the power connections on the sides of the drive. 4) Connect all cables from the control terminals of the drive (analogue inputs and outputs, digital inputs and outputs, PTC input …). 5) Connect the Display by means of the ethernet cable which goes from the display to the drive. SD700 POWER ELECTRONICS 7.3.2. DOOR 7.3.3. UPPER COVER LOWER COVERS. AND Disassembly the door See the figure 7.3.3 while following the next instructions: 1) Open the door. 2) Disconnect the ethernet cable from the display. 3) Remove the display from the support of the door. 4) Disconnect the earth cable. 5) Remove the 2 special screws of the door‟s hinges M6x12, which join the door to the side of the drive. 6) Disassembly of the upper cover and lower covers See the figure 7.3.4 while following the next instructions: 1) Unscrew the 7 Phillips M4x8 DIN-7895H screws that join the upper cover and the drive chassis. 2) In IP20 models, remove the upper cover slowly until disconnecting the power supply cable of the fans. Once disconnected the cable, remove the cover completely. 3) Unscrew the 6 Phillips M4x8 DIN-7895H screws which join the lower covers and the drive chassis. 4) Remove the lower covers. Remove the door. Figure 7.3.3 Remove the door Assembly the door 1) Put the door matching the hinges with the holes of the side. 2) Insert the special screws of the door‟s hinges M6x12, which join the door to the side of the drive. Assembly of the upper cover and the lower covers 3) Put the display on the support of the door. 1) Put the lower covers as the figure 7.3.4 shows. 4) Connect the ethernet cable of the display. 2) Fix the covers to the chassis of the drive by using the 6 Phillips screws M4x8 DIN7895H that join the lower covers and the chassis. 3) Move the upper cover closer to the chassis of the drive, and connect the power supply cable of the fans. 4) Screw the upper cover to the drive chassis by using the 7 Phillips screws M4x8 DIN7895H. Figure 7.3.4 Remove the covers. SERVICE MANUAL 85 SD700 POWER ELECTRONICS 7.3.4. CONTROL BOARD Disassembly of the control board Disassembly of the control board 1) Continue with the safety conditions which are described in the previous section. The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) While replacing the control board, avoid an excessive handling of the board. See the figure 7.3.5 while reading the following instructions: 3) Pick the new control board from the static proof bag. 1) Unscrew the 6 plastic screws M3x8 DIN933, which join the control board and the plastic hexagonal spacers M3x20. 4) Put the new control board in the same place than the replaced one, matching the board holes with the hexagonal plastic spacers M3x20 (see figure 7.3.5). 2) Remove the control board by pulling it up, until disconnecting the female connectors of 40, 32 and 28 pins of the control board, from the male connectors of the power board where control board is connected. 5) Match the male connector of 40, 32 and 28 pins of the control board with the corresponding female connector of the power board and slightly push the control board down to connect the pins. 6) Once the board is properly placed, screw the 6 plastic screws M3x8 DIN-933 in the corresponding hexagonal plastic spacers M3x20. 3) Once the control board is removed, put this board into a static proof bag for a safekeeping. Figure 7.3.5 Remove the control board. 86 SERVICE MANUAL SD700 POWER ELECTRONICS 7.3.5. POWER BOARD 6) Once the board is properly placed, screw the 6 Phillips screws M3x8 DIN-7895H in the bolts of the electronic tray. Before proceeding, the control board must have been disassembled (see section 7.3.4). 7) Connect the cables to the corresponding connectors (see figure 7.3.6). See the figure 7.3.6 while reading the following instructions: 8) Put the hexagonal plastic spacers M3x20, screwing them in their corresponding bolts of the electronic tray, in order to place the control board later. Disassembly of the power board 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect all the wires connected to this board. which are Figure 7.3.6. Disconnect all connected wires from power board 3) Remove the 6 hexagonal plastic spacers M3x20, which are joined to the electronic tray, and support the control board. 4) Unscrew the 6 Phillips screws M3x8 DIN7895H. 5) Remove the power board of the drive. Assembly of the power board 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the power board, avoid an excessive handling of the board. 3) Pick the new power board from the static proof bag. 4) Put the new power board in the same place than the replaced one. 5) Put the board on the electronic tray, matching the bolts of the tray with the holes of the board (see figure 7.3.7). Figure 7.3.7. Disassembly of the power board SERVICE MANUAL 87 SD700 POWER ELECTRONICS 7.3.6. DRIVE SELECT BOARD 7.3.7. PLUGGABLE PCB OF TRIGGER THYRISTORS. Disassembly of Drive Select board Unscrew the 2 plastic screws M3x8 DIN-933, which join this board and the plastic hexagonal spacers M3x12. Disassembly of the pluggable PCB of trigger thyristors Before removing the pluggable PCB of trigger thyristos, it is necessary to remove the tray where the control and power boards are inserted. For this, remove the 4 Phillips screws M4x8 DIN-7895H, which join this tray with the sides of the drive‟s chassis. See the figure 7.3.9: 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect the 3 cables from he thyristors and the communication cable from the pluggable PCB. Figure 7.3.8. Disassembly of the Drive Select board Assembly of Drive Select board Put the drive select board on the 2 plastic hexagonal spacers M3x13 and join them with 2 plastic screws M3x8 DIN-933. Figure 7.3.9. Disassembly of the pluggable PCB of trigger thyristors. 3) Remove the 4 plastic screws M3x8 DIN933, which join the back of the board to the 4 hexagonal plastic spacers M3x10 which are inserted in the power connections board. 4) Remove the board. Disassembly of the pluggable PCB of trigger thyristors 88 SERVICE MANUAL 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the pluggable PCB of trigger thyristors, avoid an excessive handling of the board. 3) Pick the pluggable PCB of trigger thyristors from the static proof bag. SD700 POWER ELECTRONICS 7.3.8. 4) 5) 6) Put the board in the proper position as the figure 7.3.9 (c) shows, matching the holes in the hexagonal plastic spacers M3x10, and plug the board in the connector of the power connections board. Insert the 4 plastic screws M3x8 DIN-933, which join the back of the board to the hexagonal plastic spacers M3x10. Connect the cables to the thyristors and the communication cables to the power board. POWER CONNECTIONS BOARD Disassembly of the power connections board Before proceeding, you should remove the embellishers (see section 7.3.1), the tray for the boards (see figure 7.3.7), and the pluggable PCB of the trigger thyristors (see section 7.3.7). 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Remove the 9 screws that are fixed to the thyristors, the 2 screws that are fixed to the bus, and the 4 screws that are fixed to the IGBT (M5X12 DIN-7895H). 3) Remove the 3 screws that are fixed to the AC choke (M6x16 DIN-7895H). 4) Remove the 5 Phillips screws M3x6 DIN7895H. See figure 7.3.10. Figure 7.3.9 (c). Disassembly of the pluggable PCB of trigger thyristors Figure 7.3.10. Disassembly of the power connections board Assembly of the power connections board 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the power connections board, avoid an excessive handling of the board. 3) Pick the new power connections board from the static proof bag. SERVICE MANUAL 89 SD700 4) POWER ELECTRONICS Put the board in the correct position as the figure 7.3.10 shows, matching the holes with the thyristors, the choke and with the bus. 5) Insert the 5 Phillips screws M3x6 DIN7895H. 6) Insert the 9 screws which are fixed to the bus and also, the 4 screws which are fixed to the IGBT (M5X12 DIN-7895H) with a thightening pressure of 3N/m. 7) Insert the screws that are fixed to the AC choke (M6x16 DIN-7895H) with a thightening pressure of 3N/m. 8) Plug the PCB of trigger thyristors. See figure 7.3.9 (c). 7.3.9. DC BUS Disassembly of DC Bus Before proceeding, you should remove the embellishers (see section 7.3.1), the tray for the boards (see figure 7.3.7), the pluggable PCB of trigger thyristors (see section 7.3.7), and the power connections board (see figure 7.3.10). 1) Disconnect the 2 power cables from the DC bus, with the 2 screws (M5X12 DIN-7895H). 2) Remove the 4 Phillips screws M4x8 DIN7895H which join the bus and the chassis. 3) Remove the DC bus. Figure 7.3.12. Disassembly of DC Bus Assembly of DC Bus 90 SERVICE MANUAL 1) Put the bus correctly in the chassis, matching the holes. 2) Insert the 4 Phillips screws M4x8 DIN7895H that join the bus and the chassis. 3) Insert the power connections board (see figure 7.3.11). 4) Insert the 2 screws (M5X12 DIN-7895H) which join the power connections board and the DC bus. 5) Connect the two power cables to the DC bus with screws (M5X12 DIN-7895H). SD700 POWER ELECTRONICS 7.3.10. UPPER BOARD GATE DRIVE Disassembly of the upper Gate Drive board Before removing the upper Gate Drive board, you should remove the embellishers (see section 7.3.1) and the tray for the boards (see figure 7.3.7). 7.3.11. MEDIUM AND LOWER GATE DRIVE BOARD. Disassembly of the medium and lower Gate Drive board 1) Disconnect the flat cable and the phone cables. Before removing the medium and lower Gate Drive board, you should remove the embellishers (see section 7.3.1), the tray for the boards (see figure 7.3.7), the power connections board (see section 7.3.8) and the upper Gate Drive board (see section 7.3.10). 2) Remove the 6 plastic screws M3x8 DIN933. (See figure 7.3.13). See figure 7.3.13 while following the next instructions: 3) Remove the board. 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect the power cable of dV/dt chokes, the temperature cable of the IGBT‟s and the falt cable. 3) Remove the 4 screws (M5X16 DIN-7895H) that fix the IGBT to the heatsink. 4) Remove the medium and lower Gate Drive boards together (see figure 7.3.14). Figure 7.3.13. Disassembly of the upper Gate Drive board Assembly of the upper Gate Drive board 1) Put the board in the correct position (see figure 7.3.13). 2) Insert the 6 plastic screws M3x8 DIN-933. 3) Connect the flat cable and the phone cables. Figure 7.3.14. Disassembly of the medium and lower Gate Drive boards Assembly of the medium and lower Gate Drive board 1) Continue with the safety conditions which are described in the previous section. 2) Spread the heatsink area where the IGBT is going to be placed with new thermal paste. 3) Put the IGBT matching the fixing holes (see figure 7.3.14). 4) Insert the fixing screws of the IGBT (M5X16 DIN-7895H) and thighten at 5 N/m. 5) Connect the flat cable, the temperature cable of the IGBT and the power cables which are connected to the dV/dt choke. SERVICE MANUAL 91 SD700 POWER ELECTRONICS 7.3.12. CURRENT TRANSFORMERS. 7.3.13. AC CHOKE Disassembly of the AC choke Disassembly of the current transformers Before removing the transformers, you should remove the embellishers (see section 7.3.1) and the tray boards (figure 7.3.7). See the figure 7.3.15 while following the next instructions: 1) Disconnect the 3 current measurement cables of the transformers and the 3 screws (M6x16 DIN-7895H) which connect dV/dt choke to the output. 2) Remove the 3 Phillips screws M4x8 DIN7895H that join the current transformers with the chassis. 3) Remove the current transformers. In order to remove the AC choke, first, you should remove the embellishers (see section 7.3.1), the tray for the boards (see figure 7.3.7), the power connections board (see section 7.3.8), the DC bus (see section 7.3.9), and the tray where the connections board is supported (see figure 7.3.16). See the figure 7.3.17 while following the next instructions: Figure 7.3.16 Figure 7.3.15. Disassembly of the current transformers 1) It is necessary to remove the power cables in order to remove the AC choke from the drive‟s chassis. For this, remove the power cables like this (see figure 7.3.17). 2) Remove the 4 Phillips screws M6x20 DIN7895H that join the AC choke to the supports of the chassis (see figure 7.3.17). Assembly of the current transformers 1) Insert the Phillips screws M4x8 DIN-7895H and fix the transformers to the chassis. 2) Connect the transformers. 3) Put the cables of dV/dt chokes on the inside of the transformers and connect them to the output by using 3 screws (M6x16 DIN7895H) and thighten at 5 N/m. cables of the current Figure 7.3.17 92 SERVICE MANUAL SD700 POWER ELECTRONICS 3) 7.3.14. Remove the AC choke (see figure 7.3.18). DV/DT CHOKES Disassembly of the dV/dt chokes It is necessary to remove the embellishers (see section 7.3.1), the tray for the boards (see figure 7.3.7), the power connections board (see section 7.3.8), the DC Bus (see section 7.3.9), the control cable bars (see figure 7.3.21), the bar for connectios (see figure 7.3.19) and the medium bar (see figure 7.3.20). Figure 3.18. Disassembly of the AC choke Assembly of the AC choke 1) Insert the AC choke inside the chassis. 2) Fix the AC choke to the chassis by using the 4 screws M6x20 DIN-7895H. . 3) Connect the power cables to the choke as the figure 7.3.17 shows. 4) Insulate the power cables (see figure 7.3.18). Figure 7.3.19 Figure 7.3.20 1) Remove the protection bars for the control cables. Figure 7.3.21. Figure 7.3.18 Figures 7.3.21 2) Disconnect all cables which are joined to the connections bar and the three cables of dV/dt choke which go to the lower gate drive board (see figure 7.3.22). SERVICE MANUAL 93 SD700 POWER ELECTRONICS Figuea 7.3.22 Figure 7.3.25 3) Remove the 2 screws M4x8 DIN-7895H which fix the connections bar to the chassis. 4) Remove the connections bar. 5) Remove the 5 screws (M4x8 DIN-7895H) which fix the medium bar. 10) Remove dV/dt chokes. Assembly of dV/dt chokes 6) Remove the medium bar. 7) Remove the 2 screws (M4x8 DIN-7895H ) which hold the fixing bar for the fan cables to the chassis (see figure 7.3.23). 1) Put the new dV/dt chokes matching their holes and fix them at the bottom by using 4 screws (M4x8 DIN-7895H). See figure 7.3.25. 2) Fix the upper bar of dV/dt chokes with their 4 screws (M4x8 DIN-7895H) to the drive‟s chassis (see figure 7.3.24). 3) Hold the fixing bar of the fan cables with their 2 screws (M4x8 DIN-7895H) (see figure 7.3.23). 4) Fix the medium bar by using 5 screws (M4x8 DIN-7895H). See figure 7.3.20. 5) Fix the connections bar with the 2 screws (M4x8 DIN-7895H). 6) Connect the cables of dV/dt choke, the upper cables are connected to the lower gate drive board, and the lower cables are connected to the output in the connections bar. 7) Connect the remaining cables of the DC Bus and the power cables coming from the choke. Figure 7.3.23 8) Remove the screws which fix dV/dt chokes to the top of the chassis (see figure 7.3.24). Figure 7.3.24 9) 94 Remove the 4 screws (M4x8 DIN-7895H) which fix dV/dt chokes to the bottom of the chassis (see figure 7.3.25). SERVICE MANUAL SD700 POWER ELECTRONICS 7.3.15. THYRISTORS 7.3.16. FANS Disassembly of the thyristors Disassembly of the power hetasink fan Before removing the thyristors, you should remove the embellishers (see section 7.3.1), the tray for the boards (see figure 7.3.7) and the power connections board (see section 7.3.8). See the figure 7.3.26 while following the next instructions: 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect thyristors. the control cable of 3) Remove the Phillips screws M5x16 DIN7895H which join the thyristors and their heatsink. 4) Remove the thyristor. See the figure 7.3.27 while following the next instructions: 1) Disconnect the power supply fan of the fan. 2) Remove the 2 slotted cheese head screws M4x60 DIN-84 which join the power fan with the chassis. 3) Remove the fan. the Figura 7.3.27 Assembly of the power heatsink fan 1) Put the new fan and fix it with the screws. 2) Connect the power supply cable to the fan. Disassembly of the fan for the toroids Figure 7.3.26 See figure 7.3.28 while following ther next instructions: Assembly of the thyristors 1) Disconnect the power supply cable. 1) Take the new thyristors and spread with thermal-conductor paste the bottom of the thyristors. 2) Remove the 4 slotted cheese head screws M4x40 DIN-84 which join the fan with the chassis. 2) Put them over the heatsink, matching the holes of the thyristor with the holes of the heatsink as the figure 7.3.26 shows. 3) Remove the fan. 3) Insert the Phillips screws M5x16 DIN-7895H which join the thyristors with their heatsink. 4) Connect the control cables of the thyristors. Figure 7.3.28 SERVICE MANUAL 95 SD700 POWER ELECTRONICS 7.3.17. Assembly of the fan for the toroids 1) Put the new fan and fix it by using the screws. 2) Connect the power fan cable to the fan. HEATSINK Disassembly of the heatsink In order to remove the heatsink, first, you should remove the embellishers (see section 7.3.1), the tray for the boards (see figure 7.3.7), the power connections board (see section 7.3.8), the DC bus (see section 7.3.9), the upper gate drive board (see section 7.3.10), the medium and lower gate drive board (see section 7.3.11), the thyristors (see section 7.3.15), and the fans (only the fan for the power heatsink) (see section 7.3.16). 1) Remove the 2 Phillips screws M5x12 DIN7895H which fix the heatsink to the side of the chassis (see figure 7.3.29). Figure 7.3.29 2) Remove the 2 Phillips screws M5x12 DIN7895H which fix the heatsink by the top (see figure 7.3.30). Figure 7.3.30 3) 96 SERVICE MANUAL Remove the heatsink. SD700 POWER ELECTRONICS Assembly of the heatsink 7.3.18. DISCHARGING RESISTOR. 1) Put the new heatsink in the correct position and fix it with their 4 Phillips screws M5x12 DIN7895H. Disassembly of the discharging resistor 1) Take the thyristors and the lower gate drive board and spread the thermal-conductor paste on the bottom (see figure 7.3.31). In order to remove the discharging resistor, first, you should remove the embellishers (see section 7.3.1). 2) Follow all the steps described previously in order to insert all the components again. 1) Remove the 2 screws M3x6 DIN-7895H which fix the discharging resistor to the electronic tray (see figure 7.3.32). 2) Remove the discharging resistor. Figure 7.3.31 Figure 7.3.32 Assembly of the discharging resistor 1) Put the new discharging resistor in the correct position on the electronic tray. 2) Fix the discharging resistor to the electronic tray by using the 2 screws M3x6 DIN7895H. SERVICE MANUAL 97 SD700 POWER ELECTRONICS 7.3.19. BUS CAPACITORS Disassembly of the bus capacitors It is necessary to remove the DC Bus of the drive, before performing this action (see section 7.3.9). See figure 7.3.33 while following the next instructions: 1) Unscrew the 8 special hexagonal screws M5X10 which fix the capacitors to the electronic board of the bus (see figure 7.3.33). 2) Remove the electronic board. 3) Remove the capacitors which are going to be repaired. Figure 7.3.33 Assembly of the bus capacitors 1) Put the new capacitor on the ring which is inserted in the capacitor support. 2) Put the electronic board of the bus and the capacitors in the correct position. 3) Insert the screws of the capacitors with a tightening pressure of 3N/m. 98 SERVICE MANUAL SD700 POWER ELECTRONICS 7.4. SD700 FRAME 3 7) (90-115A) 7.4.1. Remove the plastic protector for the power connections. ACCESS TO THE INSIDE OF THE DRIVE. Disassembly of the embellishers In order to repair or replace any component of the drive, you should access to the inside of it. See figure 7.4.1 and figure 7.4.2 while reading the following instructions: 1) Open the door of the drive. 2) Disconnect the Display. For this, disconnect ethernet cable which joins the display and the drive. Push the tab of the RJ45 connector and pull it up. 3) Disconnect all cables from the control terminals of the drive (analogue inputs and outputs, digital inputs and outputs, PTC input …). Figure 7.4.2 Access to the inside of the drive Assembly of the embellishers 1) Place the embellishers on the supports of the drive´s sides as the figures 7.4.2 shows. 2) Screw the embellishers to the supports of the sides with 4 Phillips M4x8 DIN-7895H screws. 3) Put the plastic protector for the power connections on the sides of the drive. 4) Connect all cables from the control terminals of the drive (analogue inputs and outputs, digital inputs and outputs, PTC input …). 5) Connect the Display by means of the ethernet cable which goes from the display to the drive. Figure 7.4.1 Display connection and control terminals 4) Remove the 4 Phillips M4x8 DIN-7895H screws, with their corresponding whasers and grover whasers, which join the embellishers to the chassis of the drive. 5) In case of IP54 model of SD700 drives, disconnect the power supply of the fans that are in the embellishers. 6) Remove the embellishers. SERVICE MANUAL 99 SD700 POWER ELECTRONICS 7.4.2. DOOR 7.4.3. UPPER COVER LOWER COVERS AND Disassembly the door See the figure 7.4.3 while following the next instructions: 1) Open the door. 2) Disconnect the ethernet cable from the display. 3) Remove the display from the support of the door. 4) Disconnect the earth cable. 5) Remove the 2 special screws of the door‟s hinges M6x12, which join the door to the side of the drive. 6) Disassembly of the upper cover and lower covers See the figure 7.4.4 while following the next instructions: 1) Unscrew the 7 Phillips M4x8 DIN-7895H screws that join the upper cover and the drive chassis. 2) In IP20 models, remove the upper cover slowly until disconnecting the power supply cable of the fans. Once disconnected the cable, remove the cover completely. 3) Unscrew the 6 Phillips M4x8 DIN-7895H screws which join the lower covers and the drive chassis. 4) Remove the lower covers. Remove the door. Figure 7.4.3 Remove the door Assembly the door 1) Put the door matching the hinges with the holes of the side. 2) Insert the special screws of the door‟s hinges M6x12, which join the door to the side of the drive. Assembly of the upper cover and the lower covers 3) Put the display on the support of the door. 1) Put the lower covers as the figure 7.4.4 shows. 4) Connect the ethernet cable of the display. 2) Fix the covers to the chassis of the drive by using the 6 Phillips screws M4x8 DIN7895H that join the lower covers and the chassis. 3) Move the upper cover closer to the chassis of the drive, and connect the power supply cable of the fans. 4) Screw the upper cover to the drive chassis by using the 7 Phillips screws M4x8 DIN7895H. 100 SERVICE MANUAL Figure 7.4.4 Remove the covers SD700 POWER ELECTRONICS Assembly of the control board 7.4.4. CONTROL BOARD 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the control board, avoid an excessive handling of the board. 3) Pick the new control board from the static proof bag. 4) Put the new control board in the same place than the replaced one, matching the board holes with the hexagonal plastic spacers M3x20 (see figure 3.5 ). Disassembly of the control board The use of a static grounding wrist strap and being earthed is highly required to repair the unit. See the figure 7.4.5 while reading the following instructions: 1) Unscrew the 6 plastic screws M3x8 DIN933, which join the control board and the plastic hexagonal spacers M3x20. 2) Remove the control board by pulling it up, until disconnecting the female connectors of 40, 32 and 28 pins of the control board, from the male connectors of the power board where control board is connected. 5) Match the male connector of 40, 32 and 28 pins of the control board with the corresponding female connector of the power board and slightly push the control board down to connect the pins. 3) Once the control board is removed, put this board into a static proof bag for a safekeeping. 6) Once the board is properly placed, screw the 6 plastic screws M3x8 DIN-933 in the corresponding hexagonal plastic spacers M3x20. Figure 7.4.5 Remove the control board. SERVICE MANUAL 101 SD700 POWER ELECTRONICS 7.4.5. POWER BOARD 6) Once the board is properly placed, screw the 6 Phillips screws M3x8 DIN-7895H in the bolts of the electronic tray. Before proceeding, the control board must have been disassembled (see section 7.4.4). 7) Connect the cables to the corresponding connectors (see figure 7.4.6). See the figure 7.4.6 while reading the following instructions: 8) Put the hexagonal plastic spacers M3x20, screwing them in their corresponding bolts of the electronic tray, in order to place the control board later. Disassembly of the power board 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect all the wires connected to this board. which are Figure 7.4.6. Disconnect all connected wires from power board 3) Remove the 6 hexagonal plastic spacers M3x20, which are joined to the electronic tray, and support the control board. 4) Unscrew the 6 Phillips screws M3x8 DIN7895H. 5) Remove the power board of the drive. Assembly of the power board 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the power board, avoid an excessive handling of the board. 3) Pick the new power board from the static proof bag. 4) Put the new power board in the same place than the replaced one. 5) Put the board on the electronic tray, matching the bolts of the tray with the holes of the board (see figure 7.4.7). 102 SERVICE MANUAL Figure 7.4.7. Disassembly of the power board SD700 POWER ELECTRONICS 7.4.6. DRIVE SELECT BOARD 7.4.7. PLUGGABLE PCB OF TRIGGER THIRISTOR Disassembly of Drive Select Board Unscrew the 2 plastic screws M3x8 DIN-933, which join this board and the plastic hexagonal spacers M3x12. Disassembly of the pluggable PCB of trigger thyristors Before removing the pluggable PCB of trigger thyristos, it is necessary to remove the tray where the control and power boards are inserted. For this, remove the 4 Phillips screws M4x8 DIN-7895H, which join this tray with the sides of the drive‟s chassis. See the figure 7.4.9: 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect the 3 cables from the thyristors and the communication cable from the pluggable PCB. Figure 7.4.9. Disassembly of the pluggable PCB of trigger thyristors. Figure 7.4.8. Disassembly of the Drive Select board 3) Remove the 4 plastic screws M3x8 DIN933, which join the back of the board to the 4 hexagonal plastic spacers M3x10 which are inserted in the bus bars and the power connections board. 4) Remove the board. Assembly of Drive Select Board Put the drive select board on the 2 plastic hexagonal spacers M3x13 and join them with 2 plastic screws M3x8 DIN-933. Disassembly of the pluggable PCB of trigger thyristors 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the pluggable PCB of trigger thyristors, avoid an excessive handling of the board. 3) Pick the pluggable PCB of trigger thyristors from the static proof bag. 4) Put the board in the proper position as the figure 7.4.9 shows, matching the holes in the hexagonal plastic spacers M3x10, and plug the board in the connector of the power connections board. SERVICE MANUAL 103 SD700 POWER ELECTRONICS 5) Insert the 4 plastic screws M3x8 DIN-933, which join the back of the board to the hexagonal plastic spacers M3x10. 6) Connect the cables to the thyristors and the communication cables to the power board. Figure 7.4.9 (c). Disassembly of the pluggable PCB of trigger thyristors 7.4.8. POWER COINNECTIONS BOARD Disassembly of the power connections board Before proceeding, you should remove the embellishers (see section 7.4.1), the tray for the boards (see figure 7.4.7), the pluggable PCB of the trigger thyristors (see section 7.4.7) and the bars for the connections to the thyristors (see figure 7.4.10 a). 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Remove the 3 screws that are fixed to the AC choke (M6x16 DIN-7895H). 3) Remove the 5 Phillips screws M3x6 DIN7895H . See figure 7.4.10. Figure 7.4.10. Disassembly of the power connections board Assembly of the power connections board 104 SERVICE MANUAL 1) Continue with the safety conditions which are described in the previous section. 2) While replacing the power connections board, avoid an excessive handling of the board. 3) Pick the new power connections board from the static proof bag. 4) Put the board in the correct position as the figure 7.4.10 shows, matching the holes with the choke. 5) Insert the 5 Phillips screws M3x6 DIN7895H. 6) Insert the screws which are fixed to the AC choke (M6x16 DIN-7895H), tightening pressure of 3N/m. 7) Plug the PCB of trigger thyristors. See figure 7.4.9. SD700 POWER ELECTRONICS 7.4.9. DC BUS Disassembly of DC Bus Before proceeding, you should remove the embellishers (see section 7.4.1), the tray for the boards (see figure 7.4.7), the pluggable PCB of trigger thyristors (see section 7.4.7), and the power connections board (see figure 7.4.10). Figure 7.4.10 a 1) Disconnect the 2 power cables from the DC bus, with the 2 screws (M5X12 DIN-7895H). 2) Remove the 4 Phillips screws M4x8 DIN7895H which join the bus and the chassis. 3) Remove the DC Bus. Figure 7.4.12. Disassembly of DC Bus Assembly of DC Bus 1) Put the bus correctly in the chassis, matching the holes. 2) Insert the 4 Phillips screws M4x8 DIN7895H that join the bus and the chassis. 3) Insert the power connections board (see figure 7.4.11). 4) Insert the 2 screws (M5X12 DIN-7895H) which join the power connections board and the DC bus. 5) Connect the two power cables to the DC bus with screws (M5X12 DIN-7895H). SERVICE MANUAL 105 SD700 POWER ELECTRONICS 7.4.10. UPPER BOARD GATE DRIVE 7.4.11. IGBT. Disassembly of IGBT Disassembly of the upper Gate Drive board Before removing the upper Gate Drive board, you should remove the embellishers (see section 7.4.1) and the tray for the boards (see figure 7.4.7). 1) Disconnect the flat cable and the phone cables. 2) Remove the 8 screws M3x8 DIN-933. (See figure 7.4.13). 3) Remove the board. Before removing the IGBT‟s you should remove the embellishers (see section 7.4.1), the tray for the boards (see figure 7.4.7) and the upper gate drive board (see section 7.4.10). See the figure 7.4.13 while following the next instructions: 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect the output bars qhich are connected to the power cable of the dV/dt choke, the cable for the IGBT‟s temperature and the flat cable (see figure 7.4.13 a). 3) Remove the screws (M6x12 DIN-7895H), which fix the capacitors and the bus bar to the IGBT (see figure 7.4.14 a). 4) Remove the 4 screws (M5X16 DIN-7895H) which fix the IGBT to the heatsink. 5) Remove the IGBT. Set with Heatsink Figure 7.4.13. Disassembly of the upper Gate Drive board Figure 7.4.13 a Assembly of the upper Gate Drive board 1) Put the board in the correct position (see figure 7.4.13). 2) Insert the 8 screws M3x8 DIN-933. 3) Connect the flat cable and the phone cables. Figure 7.4.14. Disassembly the IGBT. 106 SERVICE MANUAL SD700 POWER ELECTRONICS 7.4.12. CURRENT TRANSFORMERS. Disassembly of the current transformers Before removing the transformers, you should remove the embellishers (see section 7.4.1) and the tray boards (figure 7.4.7). See the figure 7.4.15 while following the next instructions: 1) Disconnect the 3 current measurement cables of the transformers and the 3 screws (M6x16 DIN-7895H) which connect dV/dt choke to the output. 2) Remove the 6 Phillips screws M4x8 DIN7895H that join the current transformers with the chassis. 3) Remove the current transformers. Figure 7.4.14 a. Assembly of the IGBT 1) Continue with the safety conditions which are described in the previous section. 2) Spread the area of the heatsink where the IGBT is going to be placed with new thermal paste. 3) Put the IGBT matching the fixing holes (see figure 7.4.14). 4) Insert the fixing screws for the IGBT (M5X16 DIN-7895H) and tighten them at 5 N/m. 5) Connect the output bars and the capacitors with the bus bar. Figure 7.4.15. Disassembly of the current transformers Assembly of the current transformers 1) Insert the Phillips screws M4x8 DIN-7895H and fix the transformers to the chassis. 2) Connect the transformers. 3) Put the cables of dV/dt chokes on the inside of the transformers and connect them to the output by using 3 screws (M6x16 DIN7895H) and thighten at 5 N/m. cables of the current SERVICE MANUAL 107 SD700 POWER ELECTRONICS 7.4.13. AC CHOKE. 3) Remove the AC choke (see figure 7.4.18). Disassembly of the AC choke In order to remove the AC choke, first, you should remove the embellishers (see section 7.4.1), the tray for the boards (see figure 7.4.7), the power connections board (see section 7.4.8), the connection bars for the thyristors (see figure 7.4.10 a), the bus bars (see figure 7.4.17 a), the DC bus (see section 7.4.9), and the tray where the connections board is supported (see figure 7.4.16). See the figure 7.4.17 while following the next instructions: Figure 7.4.18. Disassembly of the AC choke Assembly of the AC choke 1) Insert the AC choke inside the chassis. 2) Fix the AC choke to the chassis by using the 4 screws M6x20 DIN-7895H. . 3) Connect the power cables to the choke as the figure 7.4.17 shows. 4) Insulate the power cables (see figure 7.4.18). Figure 7.4.16 1) It is necessary to remove the power cables in order to remove the AC choke from the drive‟s chassis. For this, remove the power cables like this (see figure 7.4.17). 2) Remove the 4 Phillips screws M6x20 DIN7895H that join the AC choke to the supports of the chassis (see figure 7.4.17). Figure 7.4.18 Figure 7.4.17 a. Figure 7.4.17 108 SERVICE MANUAL SD700 POWER ELECTRONICS 7.4.14. DV/DT CHOKES 3) Remove the 2 screws M4x8 DIN-7895H which fix the connections bar to the chassis. 4) Remove the connections bar. 5) Remove the 5 screws (M4x8 DIN-7895H) which fix the medium bar. 6) Remove the medium bar. 7) Remove the 2 screws (M4x8 DIN-7895H ) which hold the fixing bar for the fan cables to the chassis (see figure 7.4.23). Disassembly of dV/dt chokes It is necessary to remove the embellishers (see section 7.4.1), the tray for the boards (see figure 7.4.7), the power connections board (see section 7.4.8), the connection bars for the thyristors (see figure 7.4.10 a), the bus bars (see figure 7.4.17 a), the DC Bus (see section 7.4.9), the control cable bars (see figure 7.4.21), the bar for connectios (see figure 7.4.19) and the medium bar (see figure 7.4.20). Figure 7.4.19 Figure 7.4.23 8) Remove the screws which fix dV/dt chokes to the top of the chassis (see figure 7.4.24). Figure 7.4.20 1) Remove the protection bars for the control cables. Figure 7.4.21. Figure 7.4.24 9) Figures 7.4.21 2) Remove the 4 screws (M4x8 DIN-7895H) which fix dV/dt chokes to the bottom of the chassis (see figure 7.4.25). Disconnect all cables which are joined to the connections bar and the three cables of dV/dt choke which go to the IGBT (see figure 7.4.22). Figure 7.4.22 SERVICE MANUAL 109 SD700 POWER ELECTRONICS 7.4.15. THYRISTORS Disassembly of the thyristors Before removing the thyristors, you should remove the embellishers (see section 7.4.1), the tray for the boards (see figure 7.4.7), the connection bars for the thyristors (see figure 7.4.10 a) and the bus bars (see figure 7.4.17 a). See the figure 7.4.26 while following the next instructions: Figure 7.4.25 1) The use of a static grounding wrist strap and being earthed is highly required to repair the unit. 2) Disconnect thyristors. 3) Remove the Phillips screws M6x20 DIN7895H which join the thyristors and their heatsink. 4) Remove the thyristor. 10) Remove dV/dt chokes. Assembly of dV/dt chokes 1) Put the new dV/dt chokes matching their holes and fix them at the bottom by using 4 screws (M4x8 DIN-7895H). See figure 7.4.25. 2) Fix the upper bar of dV/dt chokes with their 4 screws (M4x8 DIN-7895H) to the drive‟s chassis (see figure 7.4.24). 3) Hold the fixing bar of the fan cables with their 2 screws (M4x8 DIN-7895H) (see figure 7.4.23). 4) Fix the medium bar by using 5 screws (M4x8 DIN-7895H). See figure 3.20. 5) Fix the connections bar with the 2 screws (M4x8 DIN-7895H). 6) Connect the cables of dV/dt choke, the upper cables are connected to the IGBT, and the lower cables are connected to the output in the connections bar. 7) 110 Connect the remaining cables of the DC Bus and the power cables coming from the choke. SERVICE MANUAL the control cable of the Figure 7.4.26 Restaurar los tiristores 1) Take the new thyristors and spread with thermal-conductor paste the bottom of the thyristors. 2) Put them over the heatsink, matching the holes of the thyristor with the holes of the heatsink as the figure 7.4.26 shows. 3) Insert the Phillips screws M6x20 DIN-7895H which join the thyristors with their heatsink. 4) Connect the control cables of the thyristors. SD700 POWER ELECTRONICS 7.4.16. FANS Disassembly of the power heatsink fan See the figure 7.4.27 while following the next instructions: 1) Disconnect the power supply fan of the fan. 2) Remove the 2 slotted cheese head screws M4x60 DIN-84 which join the power fan with the chassis. 3) Remove the fan. Assembly of the fan for the toroids 1) Put the new fan and fix it by using the screws. 2) Connect the power fan cable to the fan. Figure 7.4.27 Assembly of the power heatsink fan 1) Put the new fan and fix it with the screws. 2) Connect the power supply cable to the fan. Disassembly of the fan for the toroids See figure 7.4.28 while following ther next instructions: 1) Disconnect the power supply cable. 2) Remove the 4 slotted cheese head screws M4x40 DIN-84 which join the fan with the chassis. 3) Remove the fan. Figure 7.4.28 SERVICE MANUAL 111 SD700 POWER ELECTRONICS 7.4.17. HEATSINK Disassembly of the heatsink In order to remove the heatsink, first, you should remove the embellishers (see section 7.4.1), the tray for the boards (see figure 7.4.7), the power connections board (see section 7.4.8), the connection bars for the thyristors (see figure 7.4.10 a), the bus bars (see figure 7.4.17 a), the DC bus (see section 7.4.9), the upper gate drive board (see section 7.4.10), the IGBT‟s (see section 7.4.11), the thyristors (see section 7.4.15), and the fans (only the fan for the power heatsink) (see section 7.4.16). 1) Assembly of the heatsink 1) Put the new heatsink in the correct position and fix it with their 4 Phillips screws M5x12 DIN-7895H. 2) Take the thyristors and the lower gate drive board and spread the thermal-conductor paste on the bottom (see figure 7.4.31). 3) Follow all the steps described previously in order to insert all the components again. Remove the 2 Phillips screws M5x12 DIN7895H which fix the heatsink to the side of the chassis (see figure 7.4.29). Figure 7.4.31 Figure 7.4.29 2) Remove the 2 Phillips screws M5x12 DIN7895H which fix the heatsink by the top (see figure 7.4.30). Figure 7.4.30 3) 112 Remove the heatsink. SERVICE MANUAL SD700 POWER ELECTRONICS 7.4.18. DISCHARGING RESISTOR 7.4.19. BUS CAPACITORS Disassembly of the bus capacitors Disassembly of discharging resistor In order to remove the discharging resistor, first, you should remove the embellishers (see section 7.4.1). 1) 2) Remove the 2 screws M3x6 DIN-7895H which fix the discharging resistor to the electronic tray (see figure 7.4.32). It is necessary to remove the DC Bus of the drive, before performing this action (see section 7.4.9). See figure 7.4.33 while following the next instructions: 1) Unscrew the 12 special hexagonal screws M5X10 which fix the capacitors to the electronic board of the bus (see figure 7.4.33). 2) Remove the electronic board. 3) Remove the capacitors which are going to be repaired. Remove the discharging resistor. Figure 7.4.32 Figure 7.4.33 Assembly of the bus capacitors Assembly of the discharging resistor 1) Put the new capacitor on the ring which is inserted in the capacitor support. 1) Put the new discharging resistor in the correct position on the electronic tray. 2) Put the electronic board of the bus and the capacitors in the correct position. 2) Fix the discharging resistor to the electronic tray by using the 2 screws M3x6 DIN7895H. 3) Insert the screws of the capacitors with a tightening pressure of 3N/m. SERVICE MANUAL 113 SD700 POWER ELECTRONICS 7.5. SD700 FRAME 4. 7.5.1 ACCESS TO THE INTERIOR OF THE DRIVE. Disassembly of the covers Follow figure 3.1 and figure 3.2 while reading these instructions: 1) Open the SDrive door. 2) Disconnect the Display from the Control PCB. 3) Disconnect all control terminals (analogue inputs, digital inputs, PTC…) Figure 3.2 Access inside Assembly of the SD700 trims Figure 3.1 Disconnect the Display and the control terminals 4) Unscrew the 6 Phillips M4x8 DIN-7895H screws, which joins the trims and the SDrive chassis. 5) Unscrew the Phillips M4x12 DIN-7895H screw, which joins the side of the trim and the Formica piece. 6) 7) In IP54 models, disconnect the fan power wires, which are in the trims, before removing them. 1) Place the trims over the supports in sides of the chassis as it is shown in the figure 3.2. 2) Screw the trims to the supports of the side pannels of the chassis with 6 Phillips M4x8 DIN-7895H. 3) Screw Phillips M4x12 DIN-7895H,which joins the side of the trim and the Formica piece. 4) Place the plastic protector of the power terminals on the sides of the drive 5) Connect all the wiring of the control terminals (analogue inputs, digital inputs, PTC…). 6) Connect the Display to the Control PCB through the Ethernet wire. Disassembly of the plastic protector 1) Unscrew the 4 Phillips M4x8 DIN-7895H, which join the plastic protector and the Sdrive chassis. 2) Remove the plastic protecotr Remove the trims Assembly of the plastic protector 1) 114 SERVICE MANUAL Replace the plastic protector of the power terminals in the SDrive chassis by screwing the 4 Phillips M4x8 DIN-7895H. SD700 POWER ELECTRONICS 7.5.2 DOOR 7.5.3 UPPER AND LOWER COVERS Disassembly of the door. Disassembly of the upper and lower covers Follow figure instructions: 3.3 while reading these 1) Open the door. 2) Disconnect the ethernet Display wire. 3) Remove the Display of the door. 4) Disconnect the earth cable of the door. 5) Unscrew the 2 specials screws M6x12, which join the door and the chassis. 6) Remove the door. Follow figure instructions: 3.4 while reading these 1) Unscrew the 6 Phillips M4x8 DIN-7895H, which join the upper cover and SD700 chassis. 2) In IP20 models, remove the upper cover slowly in order to disconnect the fan supply wire. 3) Unscrew the 12 Phillips M5x10 DIN-7895H, which join the 3 lower covers and the SD700 chassis. 4) Remove the 3 lower covers. Figure 3.4 Disassembly of the upper and lower covers . Figure 3.3 Disassembly of the door. Assembly of the door Assembly of the upper cover and lower covers 1) Place the door follow the figure 3.3. 1) 2) Join the door and the SD700 chassis by screwing 2 specials screw M6x12. Screw the 3 lowers covers to the SD700 chassis with 12 Phillips screws M5x10 DIN7895H. 2) Connect the fan supply wire. 3) Place the Display on the door. 3) 4) Connect the cable. Join the upper cover and the SD700 chassis with 6 Phillips screws M4x8 DIN-7895H. SERVICE MANUAL 115 SD700 POWER ELECTRONICS 7.5.4 CONTROL BOARD Assembly of the Control Board Disassembly of the Control Board Continue to procedures. observe static safe work The use of a static grounding wrist strap and being earthed is highly required. 1) Avoid an excessive handling of the new Control PCB. Follow figure instructions: 2) Place the new Control Board on the hexagonal spacers M3x20 and fit the holes. (figure 4.5 ) 3) Push the 40, 32 y 28 pins connectors down. Do not apply force. 4) Screw the 6 plastic screws M3x8 DIN-933 in the plastic hexagonal spacers M3x20. 1) 2) 3) 3.5 while reading these Unscrew the 6 plastic screws M3x8 DIN933, which join the control PCB and the plastic hexagonal spacers M3x20. Remove the Control Board, remove the 40, 32 y 28 pin connectors, which join the Control Board and the Power Board. When the control Board is out, place it in a static proof bag for safekeeping. Figure 3.5 Disassembly of the Control Board 116 SERVICE MANUAL SD700 POWER ELECTRONICS 7.5.5 POWER BOARD Disassembly of the Power board Before proceeding, the Control Board must have been disassembled (section 7.5.4). The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 1) 3.5 while reading Disconnect all the wires, connected to this Board. these which are Figure 3.6. Removal of the Power Board wires.. 2) Remove the 6 plastic hexagonal spacers M3x20, which are inserted in the Power Board and held the control board 3) Unscrew the 5 Phillips screws M3x8 DIN7895H. 4) Figure 3.7. Disassembly of the Power Board. Remove the power PCB. Assembly of the Power Board. Continue to procedures. observe static safe work 1) Avoid excessive handling of the new Control Board. 2) Place the new power board on the electric tray and fit the board holes in the electric tray bolts. (see figure 7.6) 3) Screw the 5 Phillips screws M3x8 DIN7895H in the electric tray bolts. 4) Connect the power board wiring. (see figure 7.6) 5) Place the plastic hexagonal spacers M3x20, on the Power Board in order to insert the Control Board later. SERVICE MANUAL 117 SD700 POWER ELECTRONICS 7.5.6 DRIVE SELECT AND IGBT SELECTION MODULE 7.5.7 SNUBBER, TRIGGER AND CHARGE PROTECTION BOARD. Disassembly of the Drive Select Disassembly of the Snubber, trigger and soft charge protection board Continue to procedures. Follow figure instructions: observe 3.8 static while safe reading work these Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. The use of a static grounding wrist strap and being earthed is highly required. Follow figure 3.9(a), figure 3.9(b) and figure 3.9(c) while reading these instructions: 1) Disassembly of the IGBT selection module The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 3.5 while reading SOFT Disconnect the voltage measure cable before and after the AC Choke and the earth cable. Afterwards, unscrew the Phillips screws M4x8 DIN-7895H, which join the wire terminals and the board. these Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. Figure 3.8. Disassembly of the Drive-select and IGBT selection module Assembly of the Drive Select Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. Figure 3.9.(a) Disassembly of the Ssnubber, Trigger and Soft charge protection 2) Disconnect all output wiring (figure 3.9 (b)). 3) Unscrew the 3 plastic screws M3x8 DIN-933, which join the board and the plastic hexagonal spacers Mix placed in the Bus(+). 4) Unscrew the 3 Phillips screws on M3x8 DIN-7895H, which join the board and the hexagonal spacers Mix placed in the Bus(+). Assembly of the IGBT selection module Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. 118 SERVICE MANUAL SD700 POWER ELECTRONICS 5) Remove the Board. Figure 3.9. (b) Disassembly of the Snubber, Trigger and Soft charge protection Assembly of the Snubber, trigger and soft charge protection board Continue to procedures. observe static safe work 1) Avoid excessive handling of the new board. 2) Place the Board in the position as it is shown in the figure 3.9 (c) 3) Screw the 3 plastic screws M3x8 DIN933, which join the board and the plastic hexagonal spacers Mix. 4) Screw the 3 Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x15. 5) Connect all voltage measure cables before and after the AC chokes and the earth cable. 6) Connect all output wiring (figure 3.9(b)) Figure 3.9. (c) Disassembly of the Ssnubber, Trigger and Soft charge protection SERVICE MANUAL 119 SD700 POWER ELECTRONICS 7.5.8 OUTPUT CHOKE. 7.5.9 DCCT Disassembly of the output choke Disassembly of the DCCT Follow figure instructions: 3.10 while reading these Before proceeding, output choke must have been disassembled (section 7.5.8). 1) Unscrew the 2 Phillips screws M6x20 DIN7895H, which join the output choke wire. Follow figure instructions: 2) Remove the output choke. 1) Unscrew the 2 Phillips screws M4x12 DIN7895H, which join the DCCT and the bakelite. 2) Remove the DCCT. 3.11 while reading these Figure 3.10. Disassembly of the output choke Figure 3.11. Disassembly of the DCCT Assembly of the output choke Assembly of the DCCT 1) Place the output choke inside the plastic insulator 1) Insert the DCCT in the aluminium busbar where it will be placed. 2) Join the terminals of the cables of the output choke to their own busbars by means of 2 Phillips screws M6x20 DIN-7895H. 2) Join the DCCT to the wood bakelite by screwing 2 Phillips screws M4x12 DIN7895H. 120 SERVICE MANUAL SD700 POWER ELECTRONICS 7.5.10 CHASSIS SIDES 7.5.11. FANS POWER SUPPLY Disassembly of the chassis sides Disassembly of the fans power supply units Before proceeding to disassemble the sides, covers (section 7.5.1), the electric tray (section 7.5.5) and the upper and lower covers (section 7.5.2) must have been disassembled. . Follow figure 3.12 while reading these instructions: Before proceeding, the chassis side where the fans power supply is inserted must have been disassembled (section 7.5.10). 1) Disassemble reinforcements. the chassis 2) Unscrew the 7 hexagonal screws M8x18 DIN-933, which join the sides and the chassis. 3) Disassemble the sides. The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 3.12 while reading these 1) Disconnect the 2 fans power supply cables for the fans and the voltage measure cable 2) Unscrew the 3 Phillips screws M3x6 DIN-7895H, which join the fans power supply and the chassis side. 3) Remove the fans power supply unit. Figure 3.12. Disassembly of the chassis sides Assembly of the chassis sides Figure 3.13. Disassembly of the fan power supply unit 1) Place the sides as it is shown in the figure 1.7, so that the holes fit the ones in the chassis. Assembly of the fan power supply unit. 2) Join the sides and the chassis by means of 7 hexagonal screws M8x18 DIN-933 Continue to procedures. 3) Join the chassis reinforcements to the sides by means of 7 hexagonal screws M8x18 DIN-933 observe static safe work 1) Place the new fans supply power unit in the side of the chassis (figure 3.13) 2) Screw 3 Phillips screws M3x6 DIN7895H, which join the fan power supply unit and the side of the chassis. 3) Connect the 2 fans power supply cables for the fans and the voltage measure cable SERVICE MANUAL 121 SD700 POWER ELECTRONICS 7.5.12 OUTPUT BAKELITE. 7.5.13 DC BUS Disassembly of the output bakelite Disassembly of the DC Bus Before proceeding, covers (see section 7.5.1) and electric tray (section 7.5.5) must have been disassembled. Before proceeding, snubber, trigger and soft charge board (section 7.5.7) and Bus output terminals (section 7.5.12) must have been disassembled. Follow figure instructions: 1) 3.14 while reading these Unscrew the 2 Phillips screws M6x20 DIN-7895H, which join the Bus output terminals and the DC Bus. 2) Unscrew the 4 Phillips screws M4x18 DIN-7895H, which join the output bakelite and the chassis sides. 3) Remove the ourput bakelite. Follow figure 3.15 (a), figure 3.15 (b) and figure 3.15 (c) while reading these instructions: 1) Remove the electronic tray, where the Control Board and Power Board are inserted, by unscrewing the 4 Phillips screws M4x8 DIN-7895H, which join this tray and the chassis sides. Figure 3.15. Disassembly of the DC Bus (a) 2) Disassembled the Snubber capacitors by unscrewing the Phillips screws M6x12 DIN7895H, which join the snubbers capacitors and the DC Bus. 3) Remove the plastic hexagonal spacers Mix3x10, which are inserted in the DC bus (+) and where the Snubber PCB leans 4) Remove the plastic hexagonal spacers Mix3x15, which are inserted in the DC bus (+) and where the Snubber PCB leans Figure 3.14. Disassembly of the output bakelite Assembly of the output bakelite 122 1) Place the output bakelite in the SD700 following figure 3.14. 2) Screw 4 Phillips screws M4x18 DIN7895H, which join the output bakelite to the chassis sides. 3) Screw 2 Phillips screws M6x20 DIN7895H, which join Bus output terminals and the DC Bus. SERVICE MANUAL SD700 POWER ELECTRONICS 5) Screw 4 Phillips screws M4x8 DIN-7895H , which join the DC Bus and the SCRs heat exchanger. Figure 3.15. Disassembly of the DC Bus (b) 5) Disassemble one chassis side (section 7.5.10). 6) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the IGBTs heat exchanger. 7) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the chassis. 8) Unscrew the 4 Phillips screws M4x8 DIN7895H, which join the DC Bus and the SCRs heat exchanger. 9) Unscrew the 6 Phillips screws M6x12 DIN7895H, which join the Bus(+) and the Bus(-) and the 3 SCRs. Assembly of the DC Bus 1) Place the DC Bus on the chassis. 2) Screw 2 Phillips screws M4x8 DIN-7895H, which join the DC Bus and the IGBTs heat exchanger . 3) Screw 2 Phillips screws M4x8 DIN-7895H 4) Screw 6 Phillips screws M6x12 DIN-7895H which, join the DC Bus and the SCRs. Figure 3.15. Disassembly of the DC Bus (c) 6) Insert the plastic hexagonal spacers Mix on the DC Bus where the snubber, trigger and soft charge PCB leans. 7) Insert the plastic hexagonal spacers M3x15 on the DC Bus, where the snubber, trigger and soft charge PCB leans. 8) Place the snubbers capacitors on the back part of DC Bus (figure 3.15) by screwing the Phillips screws M6x12 DIN-7895H . 9) Insert the chassis side (section 7.5.10). 10) Insert the electronic tray, where the Power and Control Board are inserted, by means of 4 Phillips screws M4x8 DIN-7895H . SERVICE MANUAL 123 SD700 POWER ELECTRONICS 7.5.14 BUS CAPACITORS Disassembly of the Bus capacitors Before proceeding, the DC Bus must have been disassembled. (section 7.5.13 ). Follow figure instructions: 3.16 while reading these 1) Unscrew the special hexagonal screws M5x20, which join the capacitor and the Bus(+) 2) Remove the Bus(+). 3) Remove the insulator. 4) Unscrew the special hexagonal screws M5x20, which join the capacitors and the Bus (-) 5) Remove the Bus (-). 6) Remove the Bus(-) and the middle Bus insulator. 7) Unscrew the special hexagonal screws M5x20, which join the middle Bus and the capacitors. 8) Dissassemble the middle Bus. 9) Take out the capacitors of their rings. Bus(+) and Bus(-) Assembly of the Bus capacitors 124 1) Place the new capacitors in their rings. 2) Insert the middle Bus (figure 3.16). 3) Screw the special hexagonal screws M5x20. 4) Insert the Bus(-) and the middle Bus insulator. 5) Insert the Bus (-) (figure 3.16). 6) Screw special hexagonal screws M5x20 which join with Bus (-) to the capacitors. 7) Place the Bus (+) and Bus (-) insulator. 8) Insert the Bus (+) (figure 3.16). 9) Screw special hexagonal screws M5x20 , which join with Bus (+) to the capacitors. SERVICE MANUAL Figure 3.16. Disassembly of the Bus capacitors SD700 POWER ELECTRONICS 7.5.15 IGBTS CONNECTOR BOARD Disassembly of the IGBTs connector board. The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 3.17 while reading these 1) Disconnect the IGBT trigger cable, which connects this board to the Power board. 2) Disconnect the 3 NTC wires, which connect this board to the Upper Gate Drive. 3) Unscrew the 2 plastic screws M3x6 DIN-933, which join this board and the plastic hexagonal spacers M3x18 . 4) Unscrew the 2 slotted cheese head screws M3x30 DIN-84, which join this Board and the Upper Gate Drives. 5) Remove the IGBTs connector board. The plastic hexagonal spacers and the Nylon cases are not fixed anywhere, They are simply helding this board, so that take care not to lose them when the board is disassembled. Figure 3.17. Disassembly of the IGBT Connector Board Assembly of the IGBTs conector board. Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board. 2) Place the new board on the plastic hexagonal spacers M3x18 and the Nylon cases. 3) Screw 2 slotted cheese head screws M3x30 DIN-84, which fit into the Nylon cases and are joined to the hexagonal spacers M3x18, located under the upper Gate Drive. 4) Screw 2 plastic screws M3x6 DIN-933, which join this board and the plastic hexagonal spacers M3x18. 5) Connect Ithe GBT trigger cable. 6) Connect the NTC cables. SERVICE MANUAL 125 SD700 POWER ELECTRONICS 7.5.16 UPPER GATE DRIVE Disassembly of the upper Gate Drive Before proceeding, the IGBTs connector board must have been disassembled. (section 7.5.15). The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 3.18 while reading these 1) Disconnect the phone wires, which connect this board to the lower Gate Drive. 2) Unscrew the Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x18. 3) Remove the upper Gate Drive. Assembly of the upper Gate Drive Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board 2) Place the new board on the hexagonal spacers M3x18. (figure 3.18). 3) Screw 3 Phillips screws M3x8 DIN-7895H, which join this board and the hexagonal spacers M3x18. 4) Connect the phone cables. 126 SERVICE MANUAL Figure 3.18.Assembly of the upper GateDrive SD700 POWER ELECTRONICS 7.5.17. IGBT Disassembly of the IGBT 5) Unscrew the 3 Phillips screws M6x20 DIN-7895H, which join the IGBT and the bar where DCCTs are inserted. 6) Remove the bar where DCCTs are screwed. 7) Unscrew the 4 Phillips screws M5x16 DIN-7895H, which join the IGBT and the heat exchanger. 8) Remove the IGBT. Before proceeding, the upper Gate Drive board must have been disassembled. (section 7.5.17) The use of a static grounding wrist strap and being earthed is highly required. Follow figure 3.19 (a) and figure 3.19 (b) while reading these instructions : 1) Unscrew the 4 hexagonal spacers M3x18, where the upper Gate Drive is inserted. 2) Unscrew the 2 Phillips screws M6x12 DIN-7895H, which join the Snubber capacitors and the IGBTs. 3) Remove the DC Bus (section 7.5.12) 4) Remove the snubber capacitors Figure3.19. Disassembly of the IGBT (b) Assembly of the IGBT Continue to procedures. observe static safe work 1) Avoid excessive handling of the new board. 2) Take out the new IGBT from the static box . Figure 3.19. Disassembly of the IGBT(a) SERVICE MANUAL 127 SD700 POWER ELECTRONICS 3) Spread the thermal paste over the back of the IGBT 7.5.18. SOFT CHARGE DISCHARGE RESISTORS. 4) Place the IGBT on the heat exchanger. Disassembly of the soft charge and quickdischarge resistors. 5) Screw the 4 Phillips screws M5x16 DIN7895H, which join the IGBT and the heat exchanger. 6) Place the DCCT Bar as it is shown in figure 3.19. 7) Screw the 3 Phillips screws M6x20 DIN7895H, which joint the DCCT bar and the IGBT. 8) Insert the DC Bus (section 7.5.12). 9) Put the Snubber capacitor on the DC Bus. AND QUICK- Before proceeding, the upper cover (section 7.5.3),the snubber trigger and the soft charge board (section 7.5.7), and the DC Bus (section 7.5.13 ) must have been disassembled. Follow figure instructions: 10) Screw the 2 Phillips screws M6x12 DIN7895H, which join the snubber capacitors and the IGBTs. while reading these 1) Unscrew the Phillips screws M6x16 DIN-7895H, which join the bars and the SCRs. 2) Unscrew the Phillips screws M6x20 DIN-7895H, which join the bars and the AC Choke. 3) Remove all voltage measure cables after the the AC chokes by unscrewing the Phillips screws M4x8 DIN-7895H , which join these wires and the bars. 4) Unscrew the 4 Phillips screws M4x8 DIN-7895H, which join the resistors support and the chassis. 5) Remove the resistors. 11) Screw the 4 hexagonal spacers M3x18, where the Upper Gate Drive is inserted. 12) Connect the phone cables. 3.20 Assembly of the soft charge and quickdischarge resistors. 128 SERVICE MANUAL 1) Insert the resistors support in the chassis. 2) Screw the 4 Phillips screws M4x8 DIN7895H, which join the resistors support and the chassis. 3) Insert the bars (figure 20). 4) Insert all voltage measure cables after the AC chokes by screwing the Phillips screws M4x8 DIN-7895H, which join these wires and the bars. 5) Screw the Phillips screws M6x20 DIN7895H, which join the bars and the AC Choke. 6) Screw the Phillips screws M6x16 DIN7895H, which join the bars and the SCRs. SD700 POWER ELECTRONICS 7.5.19 SCRs Disassembly of the SCRs Before proceeding, the bars, which join the AC choke and the SCRs must have been disassembled (section 7.5.18) Follow figure instructions: 1) 3.21 while reading these Unscrew the 2 Phillips screws M5x12 DIN-7895H, which join the SCR with the heat exchanger. 2) Remove the SCR. Figure 3.20. Assembly of the soft charge and quickdischarge resistors. Figure 3.21. Removing SCR Disassembly of the SCRs 1) Spread the thermal paste over the lower side of the new SCR. 2) Insert the SCR in the heat exchanger (see figure 3.21). 3) Screw the 2 Phillips screws M5x12 DIN7895H, which join the SCR and the heat exchanger. SERVICE MANUAL 129 SD700 POWER ELECTRONICS 7.5.20 POWER FAN. Disassembly of the Fan support Follow figure instructions: 3.22 while eading these 1) Unscrew the Phillips screw M4x8 DIN7895H, which join the fan support and the fan box. 2) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the fan support and the output choke support. 3) Disconenct fthe fan power cable. 4) Remove the fan support. Figure 7.23 (a) .Disassambly of the fan support 24VDC, 89W, 172X172 FAN Follow figure 3.23(a) instructions: while reading these Unscrew the 2 Phillips screws M4x12 DIN7895H which join the power fan with its support. Figure 3.23 (b) . Removing fan support Assembly of the Fan power support Figure 3.22. Disassambly of the fan support Disassembly of the fan support 24VDC, 2A, 48W, 172X172 FAN Follow figure instructions: 3.23(a) while reading these Unscrew the 2 slotted cheese head screws M4x60 DIN-84, which join the power fan and its support. 130 SERVICE MANUAL 1) Before inserting the fan support in the fan box, connect the fan power wire, and then insert the fan support in the fan box. 2) Screw the 2 Phillips screws M4x8 DIN7895H, which join the fan support and the output choke support. 3) Screw Phillips screw M4x8 DIN-7895H, which join the fan support with fan box. SD700 POWER ELECTRONICS 7.5.21 AC CHOKE 7.5.22 HEAT EXCHANGERS Disassembly of the AC Choke Disassembly of the heat exchangers Before proceeding, the bars which join the AC choke and the SCRs (section 7.5.18) and the upper cover (section 7.5.3) must have been disassembled. Before proceeding, SCRs (section 7.5.19) and IGBTs (section 7.5.17) must have been disassembled. Follow figure instructions: 1) 2) 3) 4) 3.24 while reading these Follow figure instructions: 3.25 while eading these 1) Disconnect the power wires to the input terminals, because the wires are not long enough to remove the AC choke. Disconnect the thermal wire of SCRs heat exchanger. 2) Unscrew the 4 Phillips screws M6x16 DIN-7895H, which join the AC choke and the chassis. Unscrew the 4 Phillips screws M6x16 DIN7895H, which join SCRs heat exchanger and the chassis. 3) Remove the SCRs heat exchanger. Take the AC choke out of the chassis, and disconnect the 3 power wires by unscrewing the hexagonal screws M8x25 DIN-961, which join the power wires and the AC choke. 4) Unscrew the 2 Phillips screws M5x16 DIN7895H, which join the output IGBTs bakelite and the IGBTs heat exchanger. 5) Remove the output IGBTs bakelite. Remove the AC choke. 6) Unscrew the 6 Phillips screws M6x16 DIN7895H, which join IGBTs heat exchanger and the chassis. 7) Remove the IGBTs heat exchanger. Figure 3.24 . Disassembly of the AC choke Assembly of the AC choke 1) Bring near the AC choke to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN-961. 2) Insert the AC choke in the chassis and screw the 4 Phillips screws M6x16 DIN7895H, which join the AC choke and the chassis. Figure 3.25 .Disassembly of the heat exchangers. SERVICE MANUAL 131 SD700 POWER ELECTRONICS 7.6. SD700 FRAME 5. 7.6.1 ACCESS INSIDE. Disassembly of the covers Follow figure 4.1 and figure 4.2 while reading these instructions: 1) Open the SDrive door. 2) Disconnect the Display from the Control PCB. 3) Disconnect all control terminals (analogue inputs, digital inputs, PTC…) Figure 4.2 Removal of the covers Assembly of the SD700 Covers 1) Place the covers on the chassis as it is shown in figure 4.2. 2) In IP54 models, connect the fan power wires, which are in the covers before placing them. 3) Screw the 2 Phillips screws M4x12 DIN7895H, which join the covers and the upper part of the chassis. 4) Screw the 2 Phillips screws M4x8 DIN7895H, which join the covers and lower part of the chassis. 5) Unscrew the 2 Phillips screws M4x12 DIN7895H, which join the cover and the upper part of the chassis. Connect control terminals (analogue inputs, digital inputs, PTC…). 6) Connect the Display to the Control PCB. Unscrew the 2 Phillips screws M4x8 DIN7895H, which joint the cover and the lower part of the chassis Removal of the plastic protector Figure 4.1 Disconnect the Display and the control terminals 4) 5) 8) In IP54 models, disconnect the fan power wires, which are in the covers before disassembling them 9) Remove the covers 1) Unscrew the 4 Phillips M4x8 DIN-7895-H, which join the plastic protector and the SDrive chassis. 2) Remove the plastic protector. Assembly of the plastic protector 1) 132 SERVICE MANUAL Place the power terminals plastic protector on the SDrive chassis by screwing 4 Phillips M4x8 DIN-7895H. SD700 POWER ELECTRONICS 7.6.2 UPPER COVER. 7.6.3 CONTROL BOARD Disassembly of the upper cover Disassembly of the Control Board Follow Figure instructions: 4.4 while reading these 1) Unscrew the 6 Phillips M4x8 DIN-7895H, which join the upper cover and the SD700 chassis. 2) In IP20 models, before removing the upper covers The fans supply wire must have been disconnected Therefore, separate some the upper cover from the chassis, disconnect the wire and then remove the upper cover. The use of a static grounding wrist strap and being earthed is highly required. Follow Figure instructions: 4.4 while eading these 1) Unscrew the 6 plastic screws M3x8 DIN933, which join the control PCB and the plastic hexagonal spacers M3x20. 2) Remove the Control Board by disconnecting the 40, 32 y 28 pin connectors, which join the Control Board and the Power Board. 3) When the control Board has been already disassembled, place it in a static proof bag for safekeeping. Figure 4.3 Removal of the upper covers Assembly of the upper cover 1) In IP20 models, connect the fans supply wire. 2) Join the upper cover and the SD700 chassis by screwing the 6 Phillips screw M4x8 DIN7895H. Figure 4.4 Disassembly of the Control Board Assembly of the Control Board Continue to procedures. observe static safe work 1) Avoid excessive handling of the new Control Board. 2) Place the new Control Board on the hexagonal spacers M3x20, (figure 4.5 ) 3) Push down the 40, 32 y 28 pin connectors till they fit in the connectors of the Power Board. Do not apply force. 4) Screw the 6 plastic screws M3x8 DIN-933 in the plastic hexagonal spacers M3x20. SERVICE MANUAL 133 SD700 POWER ELECTRONICS 7.6.4 POWER BOARD Disassembly of the Power board Before proceeding, the Control Board must have been removed (section 7.6.3). The use of a static grounding wrist strap and being earthed is highly required. Follow figure 4.5 while eading these instructions: 1) Disconnect all the wires, connected in this Board. which are Figure 4.5. Disconnection of all Power Board wires.. 2) Remove the 6 plastic hexagonal spacers M3x20 inserted in the Power Board. 3) Unscrew the 5 Phillips screws M3x8 DIN7895H. 4) Disassemble the Power Board. Assembly of the Power Board. Continue to procedures. observe static safe work 1) Avoid excessive handling of the new Power PCB. 2) Place the new Power Board on the electric tray and fit the holes in the electric tray bolts. (figure 7.6) 3) Screw the 5 Phillips screws M3x8 DIN7895H on the electric tray bolts. 4) Connect the Power Board wiring (figure 7.6). 5) Place the plastic hexagonal spacers M3x20 on the Power Board, so that the Control Board can be inserted later. 134 SERVICE MANUAL Figure 4.6. Disassembly of the Power Board. SD700 POWER ELECTRONICS 7.6.5 DRIVE SELECT AND IGBT SELECTION MODULE 7.6.6 SNUBBER, TRIGGER AND CHARGE PROTECTION BOARD. Disassembly the Drive Select Disassembly of the Snubber, trigger and soft charge protection board The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 4.7 while reading SOFT Follow figure 4.8 (a), figure 4.8 (b) and figure 4.8 (c) while reading these instructions: these 1) Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. Disconnect the voltage measure cable before and after the AC chokes by the Phillips screws M4x8 DIN-7895H, which join the cable terminals and the Board. Disassembly of the IGBT selection module The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 4.7 while reading these Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. Figure 4.8(a). Disassembly of the Snubber, Trigger and Soft Charge protection 2) Disconnect all output wiring (figure 4.8(b)). Figure 4.7. Remove Drive-select and IGBT selection module Assembly of the Drive Select Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. Assembly of the IGBT selection module Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. Figure 4.8.(b) Disassembly of the Snubber, Trigger and Soft Charge protection SERVICE MANUAL 135 SD700 POWER ELECTRONICS 3) Unscrew the 3 Phillips screws on M3x8 DIN-7895H, which join the board and the hexagonal spacers M3x10, placed in the Bus(+). 4) Unscrew the 3 Phillips screw M3x8 DIN7895H, which join the board and the hexagonal spacers M3x10, placed in the Bus(+). 5) Remove the Board. Assembly of the Snubber, Trigger and Soft Charge protection board 1) Avoid an excessive handling of the new board. 2) Place the Board in the position shown in the figure 4.8 (c) 3) Screw the 3 screw M3x8 DIN-7895H, which join the board and the hexagonal spacers M3x10. 4) Screw the 3 Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x15. 5) Connect all input wiring (voltage measure cable before and after the AC Chokes) by screwing the Phillips screw M4x8 DIN7895H, which joins the wire terminals and the board (figure 4.8(a)). 6) Connect all output wiring (figure 4.8(b)) Figure 4.8. (c) Disassembly of the Snubber, Trigger and Soft Charge protection 136 SERVICE MANUAL SD700 POWER ELECTRONICS 7.6.7 FANS POWER SUPPLY. 7.6.8 OUTPUT CHOKE. Disassembly of the fans power supply Disassembly of the output choke The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: Follow figure instructions: 1) Remove the fan tray by screwing the 4 Phillips screws M4x8 DIN-7895H, which join this tray and the chassis sides. In IP54 models, before disassembling the fan tray, the fan power wire must have been disconnected (IP00 and IP20 models have not any fan in this tray). 2) Unscrew the 2 hexagonal screws M8x25 DIN-933, which join the output choke and DCCT bar and output bar. 3) Remove the output choke 4.10 while reading these 1) Disconnect the 2 fans power wires, and the power wire of the fan power supply. 2) Unscrew the 3 Phillips screws M3x6 DIN7895H, which join the fans power supply and the fan tray. 3) Remove the fan power supply. 3.10 while reading these Figure 4.11. Disassembly of the output choke Figure 4.10. Disassembly of the fans power supply. Assembly of the fans power supply. Continue to procedures. observe static safe work 1) Place the new fans power supply in the fan tray. 2) Screw the 3 Phillips screws M3x6 DIN7895H, which join the fans power supply and the fan tray. 3) Connect the 2 fans power wires and the power wire. Assembly of the output choke 1) Insert the output choke as it is shown in figure 4.11. 2) Connect the terminals of the output choke wire to the DCCT bar and output bar by screwing the 2 hexagonal screws M8x25 DIN 933. 3) Insert the fan tray by screwing the 4 Phillips screws M4x8 DIN-7895H, which join this tray and the chassis. SERVICE MANUAL 137 SD700 POWER ELECTRONICS 7.6.9 DCCT 7.6.10 CHASSIS SIDES Disassembly of the DCCT Disassembly of the chassis sides Before proceeding, the output choke must have been disassembled (section 7.6.8). Before proceeding, covers (section 7.6.1), the electric tray (section 7.6.12), the fan tray (section 7.6.8) ,the output bakelite (section 7.6.12) and the upper and lower covers (section 7.6.2) must have been disassembled. Follow figure instructions: 4.12 while reading these 1) Unscrew the 2 Phillips screws M4x12 DIN7895H, which join the DCCT and the DCCT bakelite. 2) Disconnect the current measure cable. 3) Disassemble the DCCT. Follow figure instructions: 4.13 while reading these 1) Disassemble the chassis reiforcements. 2) Unscrew the 4 hexagonal screws M8x18 DIN-933, which join the sides to the chassis. 3) Remove the sides. Figure 4.13. Disassembly of the chassis sides Assembly of the chassis sides Figure 4.12. Disassembly of the DCCT Assembly of the DCCT 1) Insert the new DCCT in the DCCT bakelite. 2) Join the DCCT and the DCCT bakelite by screwing the 2 Phillips screws M4x12 DIN7895H. 3) Connect the current measure cable. 138 SERVICE MANUAL 1) Join the sides and the chassis by screwing the 7 hexagonal screws M8x18 DIN-933. 2) Join the chassis reiforcements. SD700 POWER ELECTRONICS 7.6.11 OUTPUT BAKELITE. 7.6.12 DC BUS Disassembly of the output bakelite Disassembly of the DC Bus Before proceeding, the covers (see section 7.6.1) and the electric tray (see section 7.6.12) must have been disassembled. Before proceeding, the Snubber, Trigger and Soft Charge board (see section 7.6.6) and the Bus output terminals (see section 7.6.11) must have been disassembled. Follow figure instructions: 1) 4.14 while reading these Unscrew the 2 Phillips screws M6x20 DIN7895H, which join the Bus output terminals and the DC Bus. 2) Unscrew the 4 Phillips screws M4x18 DIN7895H, which join the output bakelite and the chassis sides. 3) Remove the output bakelite. Follow figure 4.15 (a), 4.15 (b) and 4.15 (c) while reading these instructions: 1) Disassemble the electronic tray, where the Control and Power Board are inserted, by unscrewing the 4 Phillips screws M4x8 DIN7895H, which join this tray and the chassis sides. 2) Disassemble the Snubbers capacitors by unscrewing the Phillips screws M6x12 DIN7895H, which join the Snubbers capacitors and the DC Bus. 3) Remove the hexagonal spacers M3x10 inserted in the DC Bus, which are inserted in the DC bus (+), where the Snubber, Trigger and Soft Charge Board leans. 4) Remove the hexagonal spacers M3x15, which are inserted in the DC bus (+), inserted in the DC Bus, where the front of the Snubber, Trigger and Soft Charge Board leans. 5) Disassemble one chassis side (see section 7.6.10). 6) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the IGBTs heat exchanger 7) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the chassis 8) Unscrew the 4 Phillips screws M4x8 DIN7895H, which join the DC Bus and the SCRs heat exchanger 9) Unscrew the 6 Phillips screws M6x12 DIN7895H, which join the Bus(+) and the Bus(-) with the 3 SCRs. Figure 4.14. Disassembly of the output bakelite Assembly of the output bakelite 1) Insert the output bakelite in the SD700 following figure 4.14. 2) Screw the 4 Phillips screws M5x16 DIN7895H, which join the output bakelite and the chassis sides. 3) Screw the 2 Phillips screws M6x20 DIN7895H, which join the Bus output terminals and the DC Bus Assembly of the DC Bus 1) Place the DC Bus on the chassis. 2) Screw the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the IGBTs heat exchanger. 3) Screw the 4 Phillips screws M4x8 DIN7895H, which join the DC Bus and the chassis. SERVICE MANUAL 139 SD700 POWER ELECTRONICS 4) Screw the 6 Phillips screws M6x12 DIN7895H, which join the DC Bus and the SCRs. 5) Screw the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the SCRs heat exchanger. 6) Insert the plastic hexagonal spacers M3x10 on the DC Bus, where the back of the Snubber, Trigger and Soft Charge Board leans. 7) Insert the hexagonal spacers M3x15 on the DC Bus, where the front of the Snubber, Trigger and Soft charge Board leans. 8) Place the Snubbers capacitors on the back of the DC Bus (see figure 4.15) by screwing the Phillips screws M6x12 DIN-7895H. 9) Insert the chassis side (see section 7.6.10). 10) Insert the electronic tray, where the Power and the Control Board are joined, by screwing the 4 Phillips screws M4x8 DIN7895H. Figure 4.15. Disassembly of the DC Bus (a) 140 SERVICE MANUAL Figure 4.15. Disassembly of the DC Bus (b) Figure 4.15. Disassembly of the DC Bus (c) SD700 POWER ELECTRONICS 7.6.13 BUS CAPACITORS Disassembly of the Bus capacitors Before proceeding, the DC Bus must have been disassembled (section 7.6.12). Follow figure instructions: 3.16 while reading these 1) Unscrew the specials hexagonal screws M5x20, which join the capacitor and the Bus(+) 2) Remove the Bus(+) 3) Remove the Bus(+) and Bus(-) insulator. 4) Unscrew the special hexagonal screws M5x20 which join with capacitor to the Bus (-). 5) Remove the Bus (-). 6) Remove the Bus(-) and the middle Bus insulator. 7) Unscrew the special hexagonal screws M5x20, which join the middle Bus and the capacitors. 8) Remove the middle Bus. 9) Take out the capacitors of their rings. Assembly of the Bus capacitors 1) Place the new capacitors on their rings . 2) Insert the middle Bus (figure 3.16). 3) Screw the M5x20. 4) Insert the Bus(-) and middle Bus insulator. 5) Insert the Bus (-) (figure 3.16). 6) Screw the special hexagonal screws M5x20, which join the Bus (-) and the capacitors. 7) Place the Bus (+) and the Bus (-) insulator. 8) Insert the Bus (+) (figure 3.16). 9) Screw the special hexagonal screws M5x20, which join the Bus (+) and the capacitors. special hexagonal Figure 4.15. Disassembly of the Bus capacitors. screws SERVICE MANUAL 141 SD700 POWER ELECTRONICS 7.6.14 IGBTS CONNECTOR BOARD Disassembly of the IGBTs connector board. The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 4.16 while eading these 1) Disconnect the IGBT trigger cable, which connects this board to the Power board. 2) Disconnect the 3 NTC wires, which connect this board to the upper Gate Drive. 3) Unscrew the 2 plastic screws M3x6 DIN933, which join this board and the plastic hexagonal spacers M3x18. 4) Unscrew the 2 slotted cheese head screws M3x30 DIN-84, which join this Board and the Upper Gate Drives. 5) Remove the IGBTs connector board. The plastic hexagonal spacers and the Nylon cases are not fixed anywhere, They are simply helding this board, so that take care not to lose them when the board is disassembled Assembly of the IGBTs connector board. Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board. 2) Place the new board on the plastic hexagonal spacers M3x18 and Nylon cases. 3) Screw the 2 slotted cheese head screws M3x30 DIN-84, which go through the Nylon cases and are joined to the hexagonal spacers M3x18, located under the Upper Gate Drive. 4) Screw the 2 plastic screws M3x6 DIN-933, which join this board and the plastic hexagonal spacers M3x18. 5) Connect the IGBT trigger cable. 6) Connect the NTC cables. 142 SERVICE MANUAL Figure 4.16. Disassembly of the IGBT Connector Board SD700 POWER ELECTRONICS 7.6.15 UPPER GATE DRIVE Assembly of the Upper Gate Drive Before proceeding, the IGBTs connector board must have been removed removed. (section 7.6.14 ). The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 4.17 while reading these 1) Disconnect the phone cables, which connect this board to the lower Gate Drive. 2) Unscrew the Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x18. 3) Remove the Upper Gate Drive. Assembly of the Upper Gate Drive Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board 2) Place the next board on the hexagonal spacers M3x18. (figure 4.17). 3) Screw the 3 Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x18. 4) Connect the phone cables. Figure 4.17. Assembly of the Upper Gate Drive SERVICE MANUAL 143 SD700 POWER ELECTRONICS 7.6.16. IGBT 10) Screw the 4 hexagonal spacers M3x18, where the Upper Gate Drive is inserted. Disassembly of the IGBT Before proceeding, the Upper Gate Drive board must have been disassembled. (section 7.6.15). The use of a static grounding wrist strap and being earthed is highly required. Follow figure 4.17 (a) and figure 4.17 (b) while reading these instructions: 1) Unscrew the 4 hexagonal spacers M3x18, where the Upper Gate Drive is inserted. 2) Unscrew the 2 Phillips screws M6x12 DIN7895H, which join the Snubber capacitors and the IGBTs. 3) Remove the DC Bus (section 7.6.12) 4) Remove the Snubber capacitors. 5) Unscrew the 3 Phillips screws M6x20 DIN7895H, which join the IGBT and the bar where DCCTs are inserted. 6) Remove the bar, where the DCCTs are inserted. 7) Unscrew the 4 Phillips screws M5x16 DIN7895H, which join the IGBT and the heat exchanger 8) Remove the IGBT. Assembly of the IGBT Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board. 2) Remove the new IGBT of the static box. 3) Spread the thermal paste over the IGBT lower side . 4) Place the IGBT on the heat exchanger. 5) Screw the 4 Phillips screws M5x16 DIN7895H, which join the IGBT and the heat exchanger. 6) Put the DCCT Bar as it is shown in figure 4.17. 7) Insert the DC Bus (section 7.6.12). 8) Place the Snubber capacitor on the DC Bus. 9) Screw the 2 Phillips screws M6x12 DIN7895H, which join the Snubber capacitors and the IGBTs. 144 SERVICE MANUAL Figure 4.17. Assembly of the IGBT (a) SD700 POWER ELECTRONICS 7.6.17. SOFT CHARGE DISCHARGE RESISTORS. AND QUICK- Disassembly of the soft charge and quickdischarge Before proceeding, the Upper cover (section 7.6.2), Snubber, Trigger and soft charge board (section 7.6.6), and the DC Bus (section 7.6.12) must have been disassembled. Follow figure 4.18 (a) and figure 4.18 (b) while reading these instructions: 1) Unscrew the hexagonal screws M8x25 DIN933, which join the bars and the SCRs. 2) Remove the voltage measure cable the after AC choke by unscrewing the Phillips screws M4x8 DIN-7895H , which join these wires and the bars. 3) Remove the bars. Figure 4.17. Assembly of the IGBT (b) Figure 4.18. Disassembly of the Soft charge and quick-discharge resistors (a) 4) Unscrew the 4 Phillips screws M4x8 DIN7895H, which join the resistors support and the chassis. 5) Remove the resistors. SERVICE MANUAL 145 SD700 POWER ELECTRONICS 7.6.18 SCRs Disassembly of the SCRs Before proceeding, the bars, which join the AC choke and the SCRs must have been disassembled (section 7.6.17). Follow figure instructions: 4.19 while reading these 1) Unscrew the 2 Phillips screws M5x20 DIN7895H, which join the SCR and the heat exchanger. 2) Remove the SCR. Figure 4.18. Assembly of the Soft charge and quickdischarge resistors (b) Assembly of the Soft charge and quickdischarge resistors 1) Insert the resistors support on the chassis. 2) Screw the 4 Phillips screws M4x8 DIN7895H which join the resistors support with the chassis. 3) Insert the bars (figure 4.19) 4) Insert the voltage measure cable after the AC Choke by unscrewing the Phillips screws M4x8 DIN-7895H, which join the wires and the bars. 5) 6) 146 Screw the hexagonal screws M8x25 IN-933 895H, which join the bars and the AC Choke Screw the hexagonal screws M8x25 IN-933 895H , which join the bars and the SCRs. SERVICE MANUAL Figure 4.19. Disassembly of the SCR Assembly of the SCRs 1) Spread the thermal paste on the back of new SCR. 2) Insert the SCR in the heat exchanger (see figure 4.19). 3) Screw the 2 Phillips screws M5x20 DIN7895H, which join the SCR and the heat exchanger. SD700 POWER ELECTRONICS 7.6.19 POWER FANS. Disassembly of the Fan support 24VDC, 89W, 172X172 FAN Follow figure 4.20 (a) while reading these instructions Follow figure instructions: 4.21(b) while reading these 1) Unscrew the Phillips screw M4x8 DIN7895H which joint the fan support and the fan box. Unscrew the 2 Phillips screws M4x12 DIN7895H, which join the power fan and its support. 2) Unscrew the 2 Phillips screws M4x8 DIN7895H which join the fan support and the output choke support. 3) Disconnect the fan power wire. 4) Remove the fan support. Figure 4.21 (b) . Disassembly of the power fan Assembly of the Fan support 1) Before inserting the fan support on the fan box, connect the fan power wire, and then insert the fan support in the fan box. 2) Screw the 2 Phillips screws M4x8 DIN7895H, which join the fan support and the output choke support. 3) Screw the Phillips screw M4x8 DIN-7895H, which join the fan support and the fan box. Figure 4.20. Disassembly of the fan support Disassembly of the power fan support 24VDC, 2A, 48W, 172X172 FAN Follow figure 4.21(a) instructions: while reading these Unscrew the 2 slotted cheese head screws M4x60 DIN-84, which join the power fan and its support. Figure 4.21 (a) . Disassembly of the power fan SERVICE MANUAL 147 SD700 POWER ELECTRONICS 7.6.20 AC CHOKE. Disassembly of the AC Choke Before proceeding, the bars which join the AC choke and the SCRs (section 7.6.17), the AC choke-SCR bars (section 7.6.17) and the Upper cover (section 7.6.2) must have been disassembled. Follow figure instructions: 4.22 while reading these 1) Unscrew the 4 Phillips screws M6x16 DIN7895H, which join the AC choke and the chassis. 2) Remove the AC choke out of the chassis and disconnect the 3 power wires by unscrewing the hexagonal screws M8x25 DIN-961, which join the power wires and the AC choke. 3) Remove the AC choke Figure 4.22. Disassembly of the AC choke Asembly of the AC choke 1) Bring the AC choke near to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN-961. 2) Insert the AC choke in the chassis and screw the 4 Phillips screws M6x16 DIN7895H, which join the AC choke and the chassis. 148 SERVICE MANUAL SD700 POWER ELECTRONICS 7.7. SD700 FRAME 6. 7.7.1 ACCESS INSIDE. Disassembly of the covers Follow figure 5.1 y la figure 5.2 while reading these instructions: 1) Open the SDrive door. 2) Disconnect the Display from the Control Board. 3) Disconnect all control terminals (analogue inputs, digital inputs, PTC…). Figure 5.2 Disassembly of the covers Assembly of the SD700 Covers Figure 5.1 Disconnect the Display and the control terminals 4) Unscrew the 4 Phillips screws M4x12 DIN7895H, which join the cover and the chassis upper part. 5) Unscrew the 4 Phillips screws M4x8 DIN7895H, which join the cover and the lower part of the chassis. 6) In IP54 models, disconnect the fan power wires, which are in the covers before removing them. 7) Disassemble the covers. 1) Place the covers on the chassis as it is shown in figure 5.2. 2) Screw the 4 Phillips screws M4x12 DIN7895H, which join the covers and the upper part of thechassis. 3) Screw the 4 Phillips screws M4x8 DIN7895H, which join the covers and the lower part of the chassis. 4) Connect the control terminals (analogue inputs, digital inputs, PTC…). 5) Connect the Display SERVICE MANUAL 149 Disassembly of the plastic protector 7.7.2 UPPER COVER. 1) Disassembly of the upper cover 2) Unscrew the 5 Phillips M4x8 DIN-7895-H, which join the plastic protector and the SDrive chassis . Follow figure instructions: 4.4 while reading these Remove the plastic protector 1) Unscrew the 9 Phillips M4x8 DIN-7895H, which join the upper cover and the SD700 chassis. 2) In IP20 models, pull out the upper cover slowly in order to disconnect the fans supply wire. Figure 5.4 Disassembly of the upper cover Assembly of the Upper cover Figure 5.3 Disassembly of the plastic protector Assembly of the plastic protector 1) Place the power terminals plastic protector on the SDrive chassis by screwing the 5 Phillips M4x8 DIN-7895H. 1) In IP20 models, connect the fans supply wire. 2) Join the Upper cover and the SD700 chassis by screwing the 9 Phillips screws M4x8 DIN-7895H. SD700 POWER ELECTRONICS 7.7.3 CONTROL BOARD 7.7.4 POWER BOARD Disassembly of the Control Board Disassembly of the Power Board The use of a static grounding wrist strap and being earthed is highly required. Before proceeding, the Control Board must have been disassembled (section 7.7.5). Follow figure instructions: Follow figure 5.6 (a) and figure 5.6 (b) while reading these instructions: 4.4 while reading these 1) Unscrew the 6 plastic screws M3x8 DIN933, which join the control PCB and the plastic hexagonal spacers M3x20. 2) Disconnect the 40, 32 y 28 pin connectors which join the Control Board and the Power Board and then remove the Control Board 3) Put the Control Board in a static proof bag for safekeeping. 1) Disconnect all the wires, connected to this Board. which are Figure 5.6 (a) Disconnection of the Power Board wires. 2) Remove the 6 plastic hexagonal spacers M3x20 inserted in the Power Board. 3) Unscrew the 5 Phillips screws M3x8 DIN7895H. 4) Remove the Power Board. Assembly of the Power Board. Continue to procedures. Figure 5.5 Disasembly of the Control Board Assembly of the Control Board. Continue to procedures. observe static safe observe static safe work 1) Avoid an excessive handling of the new Control Board. 2) Place the new board on the electric tray and fit the holes of the board in the electric tray bolts. (figure 5.6(a)) work 1) Avoid an excessive handling of the new Control Board. 3) Screw the 5 Phillips screws M3x8 DIN7895H on the electric tray bolts. 2) Place the new Control Board on the hexagonal spacers M3x20, fit the holes. 4) Connect the Power Board wiring. (figure 5.6(a)). 3) Push the 40, 32 y 28 pins connectors down. Do not apply force. 4) Screw the 6 plastic screws M3x8 DIN-933 in the plastic hexagonal spacers M3x20. SERVICE MANUAL 151 SD700 POWER ELECTRONICS 7.7.5 DRIVE SELECT AND IGBT SELECTION MODULE Disassembly of the Drive Select The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 5.7 while reading these Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. Disassembly of the IGBT selection module The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 5.7 while reading these Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. Figure 5.6 (b). Disassembly of the Power Board. Figure 5.7. Disassembly of the Drive-select and the IGBT selection module Assembly of the Drive Select Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. Assembly of the IGBT selection module Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. 152 SERVICE MANUAL SD700 POWER ELECTRONICS 7.7.6 SNUBBER, TRIGGER AND CHARGE PROTECTION BOARD SOFT Disassembly of the Snubber, trigger and soft charge protection board The use of a static ground wrist strap and being earthed is highly required. Follow figure 5.8 (a), figure 5.8 (b) and figure 5.8 (c) while reading these instructions: 1) 2) Disconnect the voltage measure cable before and after the AC by unscrewing the Phillips screws M4x8 DIN-7895H, which join the wire terminals and the board (figure 5.8(a)) Disconnect all the output wiring (figure 5.8(b)). Figure 5.8. (b) Disassembly of the Snubber, Trigger and Soft charge protection 3) Unscrew the 3 Phillips screws on M3x8 DIN-7895H, which join the board and the hexagonal spacers M3x10, placed in the Bus(+). 4) Unscrew the 3 Phillips screw M3x8 DIN7895H, which join the board and the hexagonal spacers M3x10, placed in the Bus(+). 5) Disassemble the Board. Figure 5.8.(a) Disassembly of the snubber, trigger and soft charge protection Figure 5.8. (c) Disassembly of the Ssnubber, Trigger and Soft Charge protection SERVICE MANUAL 153 SD700 POWER ELECTRONICS Assembly of the Snubber, Trigger and Soft charge protection board 7.7.7 FANS POWER SUPPLY. Continue to procedures. Assembly of the fans power supply observe static safe work The use of a static grounding wrist strap and being earthed is highly required. 1) Avoid an excessive handling of the new board. 2) Place the Board in the position as it is shown in Figure 4.8 (c). 1) 3) Screw the 3 screws M3x8 DIN-7895H, which join the board and the hexagonal spacers M3x10. Disconnect the 2 fans power wires, and the power wire of the fans power supply. 2) Screw the 3 Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x15. Unscrew the 3 Phillips screws M3x6 DIN7895H, which join the fans power supply and the fan tray. 3) Disassemble the fan power supply. 4) 5) Connect all the input wiring (before and after the AC Choke voltage measure cable) by screwing the Phillips screw M4x8 DIN7895H, which join the wire terminals and the board (figure 5.8 (a)) 6) Connect all the output wiring. (figure 5.8 (b)) Follow figure instructions: 5.9 while reading these Figure 5.9. Disassembly of the fans supply power. Assembly of the fans supply power Continue to procedures. 154 SERVICE MANUAL observe static safe work 1) Place the new fans supply power in the fan tray. 2) Screw the Phillips screws M3x6 DIN-7895H, which join the fans power supply and the fan tray. 3) Connect the 2 fans power wires and the fan power supply power wire. SD700 POWER ELECTRONICS 7.7.8 OUTPUT CHOKE. 7.7.9 DCCT Disassembly of the output choke Disassembly of the DCCT Follow figure instructions: 5.10 while reading these 1) Unscrew the 2 hexagonal screws M8x25 DIN-933, which join the output choke and the DCCT bar. 2) Disassemble the output choke Before proceeding, the output choke must have been disassembled (section 7.7.8). Follow figure instructions: 5.11 while reading these 1) Unscrew the 2 Phillips screws M4x12 DIN7895H, which join the DCCT and the DCCT support. 2) Disconnect the current measure cable. 3) Disassemble the DCCT Figure 5.10. Disassembly of the output choke Assembly of the output choke 1) Place the output choke as it is shown in figure 5.11. 2) Connect the terminals of the output choke wire to the DCCT bar by screwing the 2 hexagonal screws M8x25 DIN 933. Figure 5.11. Disassembly of the DCCT Assembly of the DCCT 1) 2) Place the new DCCT in the place of the old one. Join the DCCT and the DCCT support by screwing the 2 Phillips screws M4x12 DIN7895H. 3) Connect the current measure cable. SERVICE MANUAL 155 SD700 POWER ELECTRONICS 7.7.10 DC BUS Disassembly of the DC Bus Before proceeding, the Snubber, Trigger and Soft charge board must have been disassembled (section 7.7.6). Follow figure 5.12 (a), figure 5.12 (b), figure 5.12 (c) and figure 5.12 (d) while reading these instructions: 1) Disassemble the electronic tray by unscrewing the 4 Phillips screws M4x8 DIN7895H, which join this tray and the chassis sides. 2) Disassemble the snubbers capacitors by unscrewing the Phillips screws M6x12 DIN7895H which join the snubbers capacitors and the DC Bus. 3) Disassemble the hexagonal spacers M3x10, which are inserted in the DC Bus, and where the back of the Snubber, Trigger and Soft charge Board leans. 4) Disassemble the hexagonal spacers M3x15, which are inserted in the DC Bus, and where the front of the Snnuber, Trigger and soft charge Board leans. 5) Unscrew the 8 Phillips M4x8 DIN-7895H screws, which join the DC Bus and the Bridge bus. 6) Unscrew the 2 Phillips M4x8 DIN-7895H screws, which join the DC Bus and the Bus bar. 7) Unscrew the 4 Phillips screws M4x8 DIN7895H, which join the DC Bus and the chassis 8) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the SCRs heat exchanger 9) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the IGBTs heat exchanger Figure 5.12 (a) Disassembly of the DC Bus. 10) Unscrew the 6 Phillips screws M6x12 DIN7895H, which join the Bus(+) and the Bus(-) with the 3 SCRs Figure 5.12. (b) Disassembly of the DC Bus 156 SERVICE MANUAL SD700 POWER ELECTRONICS Assembly of DC Bus 1) Place the DC Bus on the chassis. 2) Screw the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the IGBTs heat exchanger. 3) Screw the 4 Phillips screws M4x8 DIN7895H, which join the DC BUS and the chassis. 4) Screw the 6 Phillips screws M6x12 DIN7895H, which join DC Bus and the SCRs. 5) Screw the 6 Phillips screws M6x12 DIN7895H, which join DC Bus and the SCRs. 6) Screw the 4 Phillips screws M4x8 DIN7895H, which join the DC Bus and the SCRs heat exchanger. 7) Insert the plastic hexagonal spacers M3x10 in the DC Bus, where the back of the Snubber, Trigger and Soft charge Board leans. 8) Insert the hexagonal spacers M3x15 in the DC Bus, where the back of the Snubber, Trigger and Soft charge Board leans. 9) Place the Snubber capacitors on the back of the DC Bus (see figure 3.15) by screwing the Phillips screws M6x12 DIN-7895H. Figure 5.12. (c ) Bus bridge. 10) Screw the 8 Phillips screws, which join the DC Bus and the Bus bridge. 11) Insert the electronic tray by screwing the 4 Phillips screws M4x8 DIN-7895H. Figure 5.12. (d) Disassembly of the DC Bus SERVICE MANUAL 157 SD700 POWER ELECTRONICS 7.7.11 BUS CAPACITORS Disassembly of the Bus capacitors Before proceeding, the DC Bus must have been disassembled. (section 7.7.10 ). Follow figure instructions: 5.13 while reading these 1) Unscrew the specials hexagonal screws M5x20, which join the capacitor and the Bus(+). 2) Remove the Bus(+) 3) Remove the Bus(+) and Bus(-) insulator. 4) Unscrew the special hexagonal screws M5x20, which join the capacitor and the Bus(-). 5) Remove the Bus (-). 6) Remove the Bus(-) and the middle Bus insulator. 7) Unscrew the special hexagonal screws M5x20, which join the middle Bus and the capacitors. 8) Remove the middle Bus. 9) Take out the capacitors of their rings. Assembly of the Bus capacitors 1) Place the new capacitors in their rings . 2) Insert the middle Bus (figure 5.12). 3) Screw the M5x20. 4) Insert the Bus(-) and the middle Bus insulator. 5) Insert the Bus (-) (figure 5.12). 6) Screw the special hexagonal screws M5x20, which join the Bus (-) and the capacitors. 7) Place the Bus (+) and the Bus (-) insulator. 8) Insert the Bus (+) (figure 5.12). 9) Screw the special hexagonal screws M5x20, which join the Bus (+) and the capacitors. Figure 5.13. Disassembly of the Bus capacitors. 158 special hexagonal SERVICE MANUAL screws SD700 POWER ELECTRONICS 7.7.12 IGBTS CONNECTOR BOARD Disassembly of the IGBTs connector board. The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 5.14 while reading these Disconnect the IGBT trigger wire, connects this board to the Power board which 1) Disconnect the 3 NTC wires, which connect this board and the upper Gate Drive 2) Unscrew the 2 plastic screws M3x6 DIN933, which join this board and the plastic hexagonal spacers M3x18. 3) Unscrew the 2 slotted cheese head screws M3x30 DIN-84, which join this Board and the upper Gate Drives. 4) Remove the IGBTs connector board. The plastic hexagonal spacers and Nylon cases are not fixed anywhere, they are simply holding this board. Take care of not loosing them when the board is disassembled Assembly of the IGBTs conector board. Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board. 2) Place the new board on the plastic hexagonal spacers M3x18 and the Nylon cases. 3) Screw the 2 slotted cheese head screws M3x30 DIN-84, which are inserted into the Nylon cases and are joined to the hexagonal spacers M3x18, located under the upper Gate Drive. 4) Screw the 2 plastic screws M3x6 DIN-933, which join this board and the plastic hexagonal spacers M3x18. 5) Connect the IGBT trigger wire. 6) Connect the NTC wires. Figure 5.14. Disassembly of the IGBT Connector Board SERVICE MANUAL 159 SD700 POWER ELECTRONICS 7.7.13 UPPER GATE DRIVE 7.7.14. IGBT Disassembly of the Upper Gate Drive Disassembly of the IGBT Before proceeding, the IGBTs connector board must have been disassembled. (section 7.7.12). Before proceeding, the upper Gate Drive board must have been disassembled. (section 7.7.14). Follow figure instructions: Follow figure 5.16 (a) and figure 5.16 (b) while reading these instructions : 5.15 while reading these 1) Disconnect the phone wires, which connect this board and the lower Gate Drive. 1) Unscrew the 4 hexagonal spacers M3x18, where the Upper Gate Drive is inserted. 2) Unscrew the Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x18. 2) Unscrew the 2 Phillips screws M6x12 DIN7895H, which join the Snubber capacitors and the IGBTs. 3) Disassemble the Upper Gate Drive. 3) Remove the DC Bus (section 7.7.10). 4) Remove the Snubber capacitors. 5) Unscrew the 3 Phillips screws M6x20 DIN7895H, which join the IGBT and the bar where DCCTs are screwed. 6) Disassemble the bar, where DCCTs are screwed. 7) Unscrew the 4 Phillips screws M5x16 DIN7895H, which join the IGBT and the heat exchanger. 8) Disassemble the IGBT. Figure 5.15. Disassembly of upper Gate Drive Assembly of the Upper Gate Drive Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board . 2) Place the new board on the hexagonal spacers M3x18. (figure 5.15). 3) Screw the 3 Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x18. 4) Connect the phone wires. Figure 5.16. (a) Disassembly of the IGBT Assembly of the IGBT Continue to procedures. 1) 160 SERVICE MANUAL observe static safe work Avoid an excessive handling of the new board. SD700 POWER ELECTRONICS 2) Put the new IGBT of the static box. 3) Spread the thermal paste over the back of the IGBT. 4) Place the IGBT on the heat exchanger. 5) Screw the 4 Phillips screws M5x16 DIN7895H, which join the IGBT and the heat exchanger. 6) Place the DCCT Bar as it is shown in figure 5.16. 7) Insert the DC Bus (section 7.7.10). 8) Place the Snubber capacitor on the DC Bus. 7.7.15. SOFT CHARGE DISCHARGE RESISTORS. AND QUICK- Soft charge and quick-discharge resistors Before proceeding, the Upper cover (section 7.7.2), Snubber, Trigger and soft charge board (section 7.7.6), and the DC Bus (section 7.7.10) must have been disassembled. Follow figure 5.17 (a) and figure 5.17 (b) while reading these instructions: 1) Unscrew the hexagonal screws M8x25 DIN933, which join the bars and the SCRs. 2) Disassemble the measure voltage wire after the AC Choke by unscrewing the Phillips screws M4x8 DIN-7895H, which join these wires and the bars. 3) Remove the bars. Figure 5.16. (b) Disassembly of the IGBT Figure 5.17(a) Disassembly of the Soft charge and quick-discharge resistors SERVICE MANUAL 161 SD700 POWER ELECTRONICS 7.7.16 SCRs 4) 5) Unscrew the 4 Phillips screws M4x8 DIN7895H, which join the support of the resistors and the chassis. Removing the SCRs Remove the resistors. Before proceeding, the bars which join the AC choke with SCRs must have been disassembled (section 7.7.15) Follow figure instructions: 5.18 while reading these 1) Unscrew the 2 Phillips screws M5x12 DIN7895H which join the SCR with the heat exchanger. 2) Disassemble the SCR. Figure 5.17(b). Disassembly of soft charge and quickdischarge resistors Disassembly of the soft charge and quickdischarge resistors. 1) Insert the support of the resistors in the chassis. 2) Screw the 4 Phillips screws M4x8 DIN7895H, which join the support of the resistors and the chassis. 3) Insert the bars (figure 5.17(a)) Disassembly of the SCRs 4) Insert the voltage measure wire after the AC Choke by unscrewing the Phillips screws M4x8 DIN-7895H, which join the wires and the bars. 1) Spread the thermal paste over the back of the new SCR. 2) Insert the SCR in the heat exchanger (figure 5.18) 3) Screw the 2 Phillips screws M5x12 DIN7895H, which join the SCR and the heat exchanger. Figure 5.18. Disassembly of the SCR 5) Screw the Phillips screws M6x20 DIN7895H, which join the bars and the AC Choke. 7) Screw the Phillips screws M6x16 DIN7895H, which join the bars and the SCRs. 162 SERVICE MANUAL SD700 POWER ELECTRONICS 7.7.17 POWER FAN 24VDC, 2A, 48W, 172X172 FAN Disassembly of the Fan support Follow figure 5.20(a) instructions: Follow figure instructions: 5.19 while reading while reading these these 1) Unscrew the Phillips screw M4x8 DIN7895H, which join the fan support and the fan box. 2) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the fan support and the output choke support. 3) Disconenct the fan power wire. 4) Disassemble the fan support. Unscrew the 2 slotted cheese head screws M4x60 DIN-84, which join the power fan and its support. Figure 5.20 (a) . Disassembly of the fan support 24VDC, 89W, 172X172 FAN Follow figure instructions: 5.20(a) while reading these Unscrew the 2 Phillips screws M4x12 DIN7895H, which join the power fan and its support. Figure 5.20 (b) . Disassembly of the fan support Assembly of the Fan power support 1) Before inserting the fan support into the fan box, connect the fan power wire. 2) Screw the 2 Phillips screws M4x8 DIN7895H, which join the fan support and the output choke support. 3) Screw the Phillips screw M4x8 DIN-7895H, which join the fan support and the fan box. Figure 5.19.Disassembly of the power fan SERVICE MANUAL 163 SD700 POWER ELECTRONICS 7.7.18 AC CHOKE. Disassembly of the AC Choke Before proceeding, the bars which join the AC choke and the SCRs (section 7.7.15) and upper cover (section 7.7.2) must have been disassembled Follow figure instructions: 5.22 while reading these 1) Unscrew the 4 Phillips screws M6x16 DIN7895H, which join the AC choke and the chassis. 2) Disassemble the AC choke of the chassis, and disconnect the 3 power wires by unscrewing the hexagonal screws M8x25 DIN-961, which join the power wires and the AC choke. 3) Disassemble the AC choke. Figure 5.22. Disassembly of the AC choke Assembly of the AC choke 1) Bring the AC choke near to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN-961. 2) Insert the AC choke into the chassis and screw the 4 Phillips screws M6x16 DIN7895H, which join the AC choke and the chassis. 164 SERVICE MANUAL SD700 POWER ELECTRONICS 7.8. SD700 FRAME 7. 7.8.1 ACCESS INSIDE. Disassembly of the covers Follow figure 6.1 and figure 6.2 while reading these instructions: 1) Open the SDrive door. 2) Disconnect the Display from the Control Board. 3) Disconnect all control terminals (analogue inputs, digital inputs, PTC…). Figure 6.2 Disassembly of the covers Assembly of the SD700 Covers Figure 6.1 Disconnect the Display and the control terminals 4) 5) 1) Place the covers on the chassis as it is shown in figure 6.2. 2) Screw the 6 Phillips screws M4x12 DIN7895H, which join the covers and the upper part of the chassis. 3) Screw the 6 Phillips screws M4x8 DIN7895H, which join the covers and the lower part of the chassis. 5) Unscrew the 6 Phillips screws M4x12 DIN7895H, which join the cover and the upper part of the chassis. Connect the control terminals (analogue inputs, digital inputs, PTC…). 6) Connect the Display Unscrew the 6 Phillips screws M4x8 DIN7895H, which join the cover and the lower part of the chassis. Disassembly of the plastic protector 6) In IP54 models, disconnect the fan power wires, which are placed in the covers before disassembling them. 1) Unscrew the 6 Phillips M4x8 DIN-7895-H, which join the plastic protector and the SDrive chassis. 7) Remove the covers. 2) Disassemble the plastic protector SERVICE MANUAL 165 SD700 POWER ELECTRONICS 7.8.2 UPPER COVER. Disassembly of the Upper Cover Follow figure instructions: 6.4 while reading these 1) Unscrew the 12 Phillips M4x8 DIN-7895H, which join the upper cover and the chassis of the SD700. 2) In IP20 models, disassemble the upper cover slowly and then disconnect the fans supply wire. Afterwards remove the Upper Cover Figure 6.3 Disassembly of the plastic protector Figure 6.4 Disassemble upper cover Assembly of the plastic protector Place the plastic protector of the power terminals in the SDrive chassis by screwing the 6 Phillips M4x8 DIN-7895H. 166 SERVICE MANUAL Assembly of the upper cover 1) In IP20 models, connect the fans supply wire. 2) Join the upper cover with SD700 chassis screwing on 12 Phillips screw M4x8 DIN7895H. SD700 POWER ELECTRONICS 7.8.3 CONTROL BOARD 7.8.4 POWER BOARD Disassembly of the Control Board Disassembly of the Power Board The use of a static grounding wrist strap and being earthed is highly required. Before proceeding, the Control Board must have been disassembled (section 7.8.3). Follow figure instructions: Follow figure 6.6 (a) and figure 6.6 (b) while reading these instructions: 6.5 while reading these 1) Unscrew the 6 plastic screws M3x8 DIN933, which join the control PCB and the plastic hexagonal spacers M3x20. 2) Disassemble the Control Board by removing the 40, 32 y 28 pin connectors, which join the Control Board and the Power Board. 3) When the control Board has been disassembled, place it in a static proof bag for safekeeping. 1) Disconnect all the wires which are connect to this Board. Figure 6.6 (a) Disassembly of the Power Board wires. 2) Remove the 6 plastic hexagonal spacers M3x20, which are inserted in the Power Board. 3) Unscrew the 5 Phillips screws M3x8 DIN7895H. 4) Disassemble the Power Board. Figure 6.5 Disassembly of the Control Board Assembly of the Control Board. Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new Control Board. 2) Place the new Control Board on the hexagonal spacers M3x20. 3) Push the 40, 32 y 28 pins connectors down. Do not apply excessive force. 4) Screw the 6 plastic screws M3x8 DIN-933 in the plastic hexagonal spacers M3x20 SERVICE MANUAL 167 SD700 POWER ELECTRONICS Assembly of the Power Board. Continue to procedures. observe static 7.8.5 DRIVE SELECT AND IGBT SELECTION MODULE safe work Disassembly of the Drive Select 1) Avoid an excessive handling of the new Control Board. The use of a static grounding wrist strap and being earthed is highly required. 2) Place the new board on the electric tray and fit the holes of the board with the electric tray bolts. (figure 6.6(a)) Follow figure instructions: 3) Screw the 5 Phillips screws M3x8 DIN7895H to the electric tray bolts. 4) Connect the power board wiring. (figure 6.6(a)). 6.7 while reading these Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. Assembly of the IGBT selection module The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 6.7 while reading these Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. Figure 6.7. Disassembly o the Drive-select and IGBT selection module Assembly of Drive Select Figure 6.6 (b). Disassembly of the Power Board. Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. Assembly of IGBT selection module Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. 168 SERVICE MANUAL SD700 POWER ELECTRONICS 7.8.6 SNUBBER, TRIGGER AND CHARGE PROTECTION BOARD SOFT Disassembly of the Snubber, trigger and soft charge protection board The use of a static grounding wrist strap and being earthed is highly required. Follow figure 6.8 (a), figure 6.8 (b) and figure 6.8 (c) while reading these instructions: 1) 2) Disconnect the voltage measure cable before and after the AC Choke by unscrewing the Phillips screw M4x8 DIN7895H, which join the wire terminals and the board (figure 6.8(a)) Disconnect all output wiring (figure 6.8(b)). Figure 6.8. (b) Disassembly of the Snubber, Trigger and Soft charge protection 3) Unscrew the 3 Phillips screws on M3x8 DIN-7895H, which join the board and the hexagonal spacers M3x10, placed in the Bus (+). 4) Unscrew the 3 Phillips screw M3x8 DIN7895H, which join the board and the hexagonal spacers M3x10, placed in the Bus(+). 5) Disassemble the Board. Figure 6.8.(a) Disassembly of the Snubber, Trigger and Soft charge protection Figure 6.8. (c) Disassembly of Snubber, Trigger and Soft charge protection SERVICE MANUAL 169 SD700 POWER ELECTRONICS Assembly of Snubber, trigger and soft charge protection board 7.8.7 FANS POWER SUPPLY. Disassembly of the fan power supply Continue to procedures. 1) 2) 3) 4) observe static safe work Avoid an excessive handling of the new board. The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 6.9 while reading these Place the Board in the position shown in figure 6.8 (c). 1) Disconnect the 2 fan power wires, and power wire of the fans power supply. Screw the 3 screw M3x8 DIN-7895H, which join the board and the hexagonal spacers M3x10. 2) Unscrew the 3 Phillips screws M3x6 DIN7895H, which join the fan power supply and the fans tray. Screw the 3 Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x15. 3) Remove the fan power supply. 5) Connect all input wiring (voltage measure wire before and after the AC Choke voltage measurement) by screwing the Phillips screw M4x8 DIN-7895H, which join the wire terminals and the board (figure 6.8 (a)) 6) Connect all output wiring. (figure 6.8 (b)) Figure 6.9. Disassembly of the fan power supply. Assembly of the fans power supply Continue to procedures. 170 SERVICE MANUAL observe static safe work 1) Place the new fans power supply in the fan tray. 2) Screw the 3 Phillips screws M3x6 DIN7895H, which join the fans power supply and the fan tray. 3) Connect the 2 fan power wires and the fan power supply power wire. SD700 POWER ELECTRONICS 7.8.8 OUTPUT CHOKE. 7.8.9 DCCT Disassembly of the Output choke Disassembly of the DCCT Follow figure instructions: 6.10 while reading these 1) Unscrew the 2 hexagonal screws M8x25 DIN-933, which join the Output choke and the DCCT bar and output bar. 2) Disassemble the output choke Before proceeding, output choke must have been disassembled (section 7.8.8). Follow figure instructions: 6.11 while reading these 1) Unscrew the 2 Phillips screws M4x12 DIN7895H, which join DCCT and the DCCT support. 2) Disconnect current measure wire. 3) Disassemble the DCCT Figure 6.10. Disassembly of the output choke Assembly of the Output choke 1) Insert the output choke as it is shown in figure 6.10 2) Connect the terminals of the wire of the output choke to the DCCT bar and the output bar by screwing the 2 hexagonal screws M8x25 DIN 933. Figure 6.11. Disassembly of the DCCT Assembly of the DCCT 1) Place the new DCCT 2) Join the DCCT and the DCCT support by screwing the 2 Phillips screws M4x12 DIN7895H. 3) Connect the current measure wire. SERVICE MANUAL 171 SD700 POWER ELECTRONICS 7.8.10 DC BUS 3) Screw the 4 Phillips screws M4x8 DIN7895H, which join the DC BUS and the chassis. 4) Screw the 6 Phillips screws M6x12 DIN7895H, which join DC Bus and the SCRs. 5) Screw the 6 Phillips screws M6x12 DIN7895H, which join DC Bus and the SCRs. 6) Screw the 4 Phillips screws M4x8 DIN7895H, which join the DC Bus and the SCRs heat exchanger. 7) Insert the plastic hexagonal spacers M3x10 on the DC Bus where the back of Snubber, Trigger and Soft charge Board leans. 8) Insert the hexagonal spacers M3x15 on the DC Bus, where the back of the Snubber, Trigger and Soft charge Board leans. 9) Place the Snubber capacitors on the back of the DC Bus (see figure 3.15) by screwing the Phillips screws M6x12 DIN-7895H. Disassembly of the DC Bus Before proceeding, the Snubber, Trigger and Soft charge board must have been disassembled (section 7.8.6). Follow figure 6.13 (a), figure 6.13 (b), figure 6.13 (c) and figure 6.13 (d) while reading these instructions: 1) 2) Disassemble the electronic tray by unscrewing the 4 Phillips screws M4x8 DIN7895H, which join this tray and the side of the chassis. Disassemble the snubber capacitors by unscrewing he Phillips screws M6x12 DIN7895H, which join the snubber capacitors and the DC Bus. 3) Disassemble the hexagonal spacers M3x10 inserted in the DC Bus, and where the back of the snubber, trigger and soft charge Board leans 4) Disassemble the hexagonal spacers M3x15 inserted in the DC Bus, where the front of the snubber, trigger and soft charge Board leans. 5) Unscrew the 8 Phillips M6x16 DIN-7895H screws, which join the DC Bus and the bus bridge. 6) Unscrew the 2 Phillips M6x16 DIN-7895H screws, which join the DC Bus and the Bus bar. 7) Unscrew the 4 Phillips screws M4x8 DIN7895H, which join the DC Bus and the chassis 8) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the SCRs heat exchanger 9) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the IGBTs heat exchanger 10) Unscrew the 6 Phillips screws M6x12 DIN7895H, which join the Bus(+) and the Bus(-) with the 3 SCRs Assembly of the DC Bus 1) Place the DC Bus in the chassis. 2) Screw the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the IGBTs heat exchanger. 172 SERVICE MANUAL 10) Screw the 8 Phillips screws M6x16 DIN7895H, which join the DC Bus and the Bus bridge. 11) Screw the 2 Phillips screws M6x16 DIN7895H, which join the DC Bus and the Bus bridge 12) Insert the electronic tray by screwing the 4 Phillips screws M4x8 DIN-7895H. SD700 POWER ELECTRONICS Figure 6.12. (c) Bus bridge. Figure 6.12 (a) Disassembly of the DC Bus. Figure 6.12. (d) Disassembly of the DC Bus Figure 6.12. (b) Disassembly of the DC Bus SERVICE MANUAL 173 SD700 POWER ELECTRONICS 7.8.11 BUS CAPACITORS Before proceeding, the DC Bus must have been disassembled. (section 7.8.10 ). Follow figure instructions: 6.13 while reading these Disassembly of the Bus capacitors 1) Unscrew the special hexagonal screws M5x20, which join the capacitor and the Bus(+). 2) Remove the Bus(+) 3) Remove the Bus (+) and the Bus(-) insulator. 4) Unscrew the special hexagonal screws M5x20, which join the capacitor and the Bus (-). 5) Remove the Bus (-). 6) Remove the Bus(-) and the middle Bus insulator. 7) Unscrew the special hexagonal screws M5x20, which join the middle Bus and the capacitors. 8) Remove the middle Bus. 9) Take out the capacitors of their rings. Assembly of the Bus capacitors 1) Place the new capacitors in their rings. 2) Insert the middle Bus (figure 6.13). 3) Screw the M5x20. 4) Insert the Bus(-) and the middle Bus insulator. 5) Insert the Bus (-) (figure 6.13). 6) Screw the special hexagonal screws M5x20, which join the Bus (-) and the capacitors. 7) Place the Bus (+) and the Bus (-) insulator. 8) Insert the Bus (+) (figure 6.13). 9) Screw special hexagonal screws M5x20, which join the Bus (+) and the capacitors. 174 special hexagonal SERVICE MANUAL screws Figure 6.13. Disassembly of the Bus capacitors. SD700 POWER ELECTRONICS 7.8.12 IGBTS CONNECTOR BOARD Disassembly of the IGBTs connector board. The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 6.14 while reading these 1) Disconnect the IGBT trigger wire, which connects this board to the Power board 2) Disconnect the 3 NTC wires, which connect this board to the upper Gate Drive 3) Unscrew the 2 plastic screws M3x6 DIN933, which join this board and the plastic hexagonal spacers M3x18. 4) Unscrew the 2 slotted cheese head screws M3x30 DIN-84, which join this Board and the Upper Gate Drives. 5) Remove the IGBTs connector board. The plastic hexagonal spacers and the Nylon cases are not fixed anywhere, they are simply holding this board. Take care of not loosing them when the board is disassembled Assembly of the IGBTs conector board. Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board. 2) Place the new board on the plastic hexagonal spacers M3x18 and the Nylon cases. 3) Screw the 2 slotted cheese head screws M3x30 DIN-84, which are inserted into the Nylon cases and are joined to the hexagonal spacers M3x18, located under the upper Gate Drive. 4) Screw the 2 plastic screws M3x6 DIN-933, which join this board and the plastic hexagonal spacers M3x18. 5) Connect the IGBT trigger wire. 6) Connect the NTC wires. Figure 6.14. Disassembly of the IGBT Connector Board SERVICE MANUAL 175 SD700 POWER ELECTRONICS 7.8.13 UPPER GATE DRIVE 7.8.14. IGBT Disassembly of upper Gate Drive Disassembly of the the IGBT Before proceeding, the IGBTs connector board must have been disassembled. (section 7.8.12). Before proceeding, the upper Gate Drive board must have been disassembled. (section 7.8.14). Follow figure instructions: Follow figure 6.16 (a) and figure 6.16 (b) while reading these instructions: 6.15 while reading these 1) Disconnect the phone wires, which connect this board to the lower Gate Drive. 1) Unscrew the 4 hexagonal spacers M3x18, where the Upper Gate Drive is inserted. 2) Unscrew the Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x18. 2) Unscrew the 2 Phillips screws M6x12 DIN7895H, which join the Snubber capacitors and the IGBTs. 3) Disassemble the Upper Gate Drive. 3) Remove the DC Bus (section 7.8.10). 4) Remove the snubber capacitors 5) Unscrew the 3 Phillips screws M6x20 DIN7895H, which join the IGBT and the bar ,where the DCCTs are screwed. 6) Remove the bar where the DCCTs are screwed. 7) Unscrew the 4 Phillips screws M5x16 DIN7895H, which join the IGBT and the heat exchanger. 8) Disassemble the IGBT. Figure 6.15. Disassembly of the Upper Gate Drive Assembly of the Upper Gate Drive Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board. 2) Place the new board on the hexagonal spacers M3x18. (figure 5.15). 3) Screw the 3 Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x18. 4) 176 Connect the phone wires. SERVICE MANUAL Figure 6.16. (a) Disassembly of the IGBT SD700 POWER ELECTRONICS Assembly of the IGBT Continue to procedures. observe 7.8.15 SCRs static safe work Disassembly of the SCRs Before proceeding, the Upper cover (section 7.8.2), the Snubber Trigger and Soft charge board (section 7.8.6), and the DC Bus (section 7.8.10) must have been disassembled. 1) Avoid an excessive handling of the new board. 2) Take out the new IGBT of the static box. 3) Spread the thermal paste over the back of the IGBT. 4) Place the IGBT on the heat exchanger. 1) 5) Screw the 4 Phillips screws M5x16 DIN7895H, which join the IGBT and the heat exchanger. Unscrew the hexagonal screws M8x25 DIN933, which join the bars and the SCRs. 2) Remove voltage measure wires after the AC choke by unscrewing the Phillips screws M4x8 DIN-7895H, which join these wires and the bars. 3) Remove the bars. 6) Place the DCCT Bar as it is shown in figure 6.16. 7) Insert the DC Bus (section 7.8.10). 8) Place the Snubber capacitor on the DC Bus. Figure 6.16. (b) Disassembly of the IGBT Follow figure 6.17(a) and figure 6.17(b) while reading these instructions: Figure 6.17(a). Disassembly of the SCR SERVICE MANUAL 177 SD700 4) 5) POWER ELECTRONICS Unscrew the 2 Phillips screws M5x12 DIN7895H which join the SCR and the heat exchanger. 7.8.16 POWER FAN Disassemble the SCR. Follow figure instructions: Disassembly of the Fan support 6.18 while reading these 1) Unscrew the Phillips screw M4x8 DIN7895H, which join the fan support and the fan box. 2) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the fan support and the output choke support. 3) Disconenct the fan power wire. 4) Remove the fan support. Figure 6.17(b). Disassembly of the SCR Assembly of the SCRs 1) Spread the thermal paste over the back of the new SCR. 2) Insert the SCR in the heat exchanger (figure 6.17). 3) Screw the 2 Phillips screws M5x12 DIN7895H, which join the SCR and the heat exchanger. 4) Insert the bars (figure 6.17(a)) 5) Insert the voltage measure wires after the AC Choke by unscrewing the Phillips screws M4x8 DIN-7895H, which join their wires and the bars. 6) Screw the Phillips screws M6x20 DIN7895H, which join the bars and the AC Choke. 7) Screw Phillips screws M6x16 DIN-7895H, which join the bars and the SCRs. 178 SERVICE MANUAL Figura 6.18.Disassembly of the Power Fan SD700 POWER ELECTRONICS 24VDC, 2A, 48W, 172X172 FAN 7.8.17 AC CHOKE Follow figure 6.19 (a) while reading these instructions: Disassembly of the AC Choke Unscrew the 2 slotted cheese head screws M4x60 DIN-84, which join the power fan and its support. Before proceeding, the bars, which join the AC choke and the SCRs (section 7.8.15) and the Upper cover (section 7.8.2) must have been disassembled. Follow figure instructions: Figure 6.19 (a) . Disassembly of the fan support 6.20 while reading these 1) Unscrew the 4 Phillips screws M6x16 DIN7895H, which join the AC choke and the chassis. 2) Remove the AC choke out of the chassis, and disconnect the 3 power wires by unscrewing the hexagonal screws M8x25 DIN-961, which join the power wires and the AC choke. 3) Disassemble the AC choke. 24VDC, 89W, 172X172 FAN Follow figure 6.19 (b) while reading these instructions: Unscrew the 2 Phillips screws M4x12 DIN7895H, which join the power fan with its support. Figure 6.20. Disasembly of the AC choke Assembly of the AC choke Figure 6.19 (b) . Removing fan support Assembly of the Fan power support 1) Before inserting the fan support in the fan box, connect the fan power wire. 2) Screw the 2 Phillips screws M4x8 DIN7895H, which join the fan support and the output choke support. 3) Screw the Phillips M4x8 DIN-7895H, which join the fan support and the fan box. 1) Place the AC choke near to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN-961. 2) Place the AC choke in the chassis and screw the 4 Phillips screws M6x16 DIN7895H, which join the AC choke and the chassis. SERVICE MANUAL 179 SD700 POWER ELECTRONICS 7.9. SD700 FRAME 8. 3) Screw the 6 Phillips screws M4x8 DIN7895H which, join the covers and the lower part of the chassis. 4) Connect the Display. 7.9.1 ACCESS INSIDE. Disassembly of the covers Follow figure 7.1 y la figure 7.2 while reading these instructions: 1) Open the SDrive door. 2) Disconnect the Display from the Control Board. 3) Disconnect all control terminals (analogue inputs, digital inputs, PTC…). Figure 7.2 Disassembly of the covers Figure 7.1 Disconnect the Display and the control terminals 4) Unscrew the 9 Phillips screws M4x12 DIN7895H, which join the cover and the chassis upper part. 5) Unscrew the 9 Phillips screws M4x8 DIN7895H, which join the cover and the lower part of the chassis. 6) In IP54 models, disconnect the fan power wires, which are in the covers before disassembling them. 7) Remove the covers. Assembly of the SD700 Covers 1) Place the covers in the chassis as is shown in the figure 7.2. 2) Screw the 6 Phillips screws M4x12 DIN7895H, which join the covers and the Upper part of the chassis. 180 SERVICE MANUAL Disassembly of the plastic protector 1) Unscrew the 7 Phillips M4x8 DIN-7895-H ,which join the plastic protector and the SDrive chassis. 2) Remove the plastic protector. Assembly of the plastic protector Place the plastic protector of the power terminals in the SDrive chassis by screwing the 7 Phillips M4x8 DIN-7895H. SD700 POWER ELECTRONICS 7.9.2 UPPER COVER Disassembly of the Upper cover Follow figure instructions: 7.4 while reading these 1) Unscrew the 14 Phillips M4x8 DIN-7895H, which join the Upper cover and the SD700 chassis. 2) In IP20 models, Disassemble the upper cover slowly in order to disconnect the fans supply wire. Figure 7.4 Disassemble the upper cover. Figure 7.3 Assembly of the plastic protector. Assembly of the Upper cover 1) In IP20 models, connect the fan supply wire. 2) Join the upper cover and the SD700 chassis by screwing the 14 Phillips screw M4x8 DIN-7895H. SERVICE MANUAL 181 SD700 POWER ELECTRONICS 7.9.3 CONTROL BOARD 7.9.4 POWER BOARD Disassembly of the Control Board Disassembly of the Power Board The use of a static grounding wrist strap and being earthed is highly required. Before proceeding, the Control Board must have been disassembled (section 7.8.3). Follow figure instructions: Follow figure 7.6 (a) and figure 7.6 (b) while reading these instructions: 7.5 while reading these 1) Unscrew the 6 plastic screws M3x8 DIN933, which join the control PCB and the plastic hexagonal spacers M3x20. 2) Disassemble the Control Board by disconnnecting the 40, 32 y 28 pin connectors, which join the Control Board and the Power Board. 3) When the control Board is out, place it in a static proof bag for safekeeping. 1) Disconnect all the wires, connected to this Board . which are Figure 7.6 (a) Disassembly of the Power Board wires. 2) Remove the 6 plastic hexagonal spacers M3x20, which are inserted in the Power Board. 3) Unscrew the 5 Phillips screws M3x8 DIN7895H. 4) Disassemble the Power Board. Assembly of the Power Board. Continue to procedures. Figure 7.5 Disassembly of the Control Board Assembly of the Control Board. Continue to procedures. observe static safe observe static safe work Avoid an excessive handling of the new Control Board. 1) Put the new board on the electric tray and fit the holes with the electric tray bolts. (figure 7.6(a)) work 1) Avoid an excessive handling of the new Control Board. 2) Screw the 5 Phillips screws M3x8 DIN7895H on the electric tray bolts. 2) Place the new Control Board on the hexagonal spacers M3x20 making the holes fit 3) Connect all the wiring of the Power board. (figure 7.6(a)). 3) Push the 40, 32 y 28 pins connectors down. Do not apply excessive force. 4) Screw the 6 plastic screws M3x8 DIN-933 in the plastic hexagonal spacers M3x20 182 SERVICE MANUAL SD700 POWER ELECTRONICS 7.9.5 DRIVE SELECT AND IGBT SELECTION MODULE Disassembly of the Drive Select The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 7.7 while reading these Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. Assembly of the IGBT selection module The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 7.7 while reading these Unscrew the 2 plastic screws M3x8 DIN-933, which join this Board and the plastic hexagonal spacers M3x13. Figure 7.6 (b). Disassembly of the Power Board. Figure 7.7. Disassembly of the Drive-select and the IGBT selection module Disassembly of the Drive Select Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. Assembly of the IGBT selection module Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN-933. SERVICE MANUAL 183 SD700 POWER ELECTRONICS 7.9.6 SNUBBER, TRIGGER AND CHARGE PROTECTION BOARD SOFT Disassembly of the Snubber, Trigger and Soft charge protection board The use of a static grounding wrist strap and being earthed is highly required. Follow figure 7.8 (a), figure 7.8 (b) and figure 7.8 (c) while reading these instructions: 1) 2) Disconnect the voltage measure wire before and after the AC Choke by unscrewing the Phillips screws M4x8 DIN-7895H which join the wire terminals and the board (figure 7.8(a)) Disconnect all output wiring (figure 7.8 (b)). Figure 7.8. (b) Disassembly of the Ssnubber, Trigger and Soft charge protection 3) Unscrew the 3 Phillips screws on M3x8 DIN-7895H, which join the board and the hexagonal spacers M3x10, which are placed in the Bus(+). 4) Unscrew the 3 Phillips screw M3x8 DIN7895H, which join the board and the hexagonal spacers M3x10, which are placed in the Bus(+). 5) Disassemble the Board. Figure 7.8.(a) Disassembly of the Snubber, Trigger and soft charge protection Figure 7.8. (c) Disassembly of the Ssnubber, Trigger and Soft charge protection 184 SERVICE MANUAL SD700 POWER ELECTRONICS Assembly of the Snubber, trigger and soft charge protection board 7.9.7 FANS POWER SUPPLY. Disassembly of the fans power supply Continue to procedures. 1) 2) 3) 4) observe static safe work Avoid an excessive handling of the new board. Put the Board in the position as it is shown in figure 7.8 (c). The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 7.9 while reading these 1) Disconnect the 2 fans power wires, and the power wire of the fans power supply. Screw the 3 screws M3x8 DIN-7895H, which join the board and the hexagonal spacers M3x10. 2) Unscrew the 3 Phillips screws M3x6 DIN7895H, which join the fans power supply and the fan tray. Screw the 3 Phillips screws M3x8 DIN7895H, which join this board and hexagonal spacers M3x15. 3) Remove the fan power supply. 5) Connect all input wiring (voltage measure wire before and after the AC Choke), by screwing the Phillips screw M4x8 DIN7895H, which join the wire terminals and the board (figure 7.8 (a)) 6) Connect all output wiring. (figure 7.8 (b)) Figure 7.9. Disassembly of the fans power supply. Assembly of the fans power supply Continue to procedures. observe static safe work 1) Put the new fans power supply in the fan tray. 2) Screw the 3 Phillips screws M3x6 DIN7895H, which join the fans supply power and the fan tray. 3) Connect the 2 fans power wires and the fan power supply power wire . SERVICE MANUAL 185 SD700 POWER ELECTRONICS 7.9.8 OUTPUT CHOKE. 7.9.9 DCCT Disassembly of the output choke Disassembly of the DCCT Follow figure instructions: 7.10 while reading these 1) Unscrew the 2 hexagonal screws M8x25 DIN-933, which join the output choke and the DCCT bar and output bar. 2) Disassemble the output choke Before proceeding, output choke must have been disassembled (section 7.9.8). Follow figure instructions: 7.11 while reading these 1) Unscrew the 2 Phillips screws M4x12 DIN7895H, which join DCCT and the DCCT support. 2) Disconnect the current measure wire. 3) Disassemble the DCCT Figure 7.11. Disassembly of the DCCT Figure 7.10. Disassembly of the output choke Assembly of the DCCT Assembly of the output choke 1) Insert the output choke as it is shown in figure 7.10 2) Connect the terminals of the output choke wire to the DCCT bar and output bar, by screwing the 2 hexagonal screws M8x25 DIN 933. 186 SERVICE MANUAL 1) Put the new DCCT in the place of the old DCCT. 2) Join the DCCT and the DCCT support by screwing the 2 Phillips screws M4x12 DIN7895H. 3) Connect the current measure wire SD700 POWER ELECTRONICS 7.9.10 DC BUS 3) Screw the 4 Phillips screws M4x8 DIN7895H, which join the DC BUS and the chassis. 4) Screw the 6 Phillips screws M6x12 DIN7895H, which join DC Bus and the SCRs. 5) Screw the 6 Phillips screws M6x12 DIN7895H, which join the DC Bus and the SCRs. Disassembly of the DC Bus Before proceeding, snubber, trigger and soft charge board must have been disassembled (section 7.9.6). Follow figure 7.12 (a), figure 7.12 (b), figure 7.12 (c), figure 7.12 (d) and figure 7.12 (e) while reading these instructions: 1) 2) 3) 4) 6) Remove the electronic tray by unscrewing the 4 Phillips screws M4x8 DIN-7895H, which join this tray and the sides of the chassis. Screw the 4 Phillips screws M4x8 DIN7895H, which join the DC Bus and the SCRs heat exchanger. 7) Remove the Snubber capacitors by unscrewing the Phillips screws M6x12 DIN7895H, which join the snubber capacitors and the DC Bus. Insert the plastic hexagonal spacers M3x10 on the DC Bus, where the back of the Snubber, Trigger and Soft charge Board leans. 8) Insert the hexagonal spacers M3x15 on the DC Bus, where the back of the Snubber, Trigger and Soft charge Board leans. 9) Put the Snubber capacitors on the back of the DC Bus (see figure 3.15) by screwing the Phillips screws M6x12 DIN-7895H. Remove the hexagonal spacers M3x10 inserted in the DC Bus where the back of the Snubber, Trigger and soft charge Board leans. Remove the hexagonal spacers M3x15 inserted in the DC Bus, where the front of the Snubber, Trigger and Soft charge Board. 10) Screw the 8 Phillips screws M6x20 DIN7895H, which join the DC Bus and the Bus bridge. 5) Unscrew the 8 Phillips M6x20 DIN-7895H screws, which join the DC Bus and the bus bridge. 11) Screw the 2 Phillips screws M6x20 DIN7895H, which join the DC Bus and the Bus bridge 6) Unscrew the 2 Phillips M6x20 DIN-7895H screws, which join the DC Bus and the Bus bar. 12) Insert the electronic tray by screwing the 4 Phillips screws M4x8 DIN-7895H. 7) Unscrew the 4 Phillips screws M4x8 DIN7895H, which join the DC Bus and the chassis 8) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the SCRs heat exchanger 9) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the IGBTs heat exchanger 10) Unscrew the 6 Phillips screws M6x12 DIN7895H, which join the Bus(+) and the Bus(-) to the 3 SCRs Assembly of the DC Bus 1) Place the DC Bus in the chassis. 2) Screw the 2 Phillips screws M4x8 DIN7895H, which join the DC Bus and the IGBTs heat exchanger. SERVICE MANUAL 187 SD700 POWER ELECTRONICS Figure 7.12. (b) Disassembly of the DC Bus. Figure 7.12 (a) Disassembly of the DC Bus. Figure 7.12. (c) Bus bridge. Figure 7.12 (b) Disassembly of the DC Bus. 188 SERVICE MANUAL SD700 POWER ELECTRONICS 7.9.11 BUS CAPACITORS Before proceeding, the DC Bus must have been disassembled. (section 7.9.10 ). Follow the figure 7.13 while reading these instructions: Figure 7.12. (d) Disassembly of the DC Bus. 1) Unscrew the special hexagonal screws M5x20, which join the capacitor and the Bus(+). 2) Remove the Bus(+) 3) Remove the Bus(+) and the Bus(-) insulator. 4) Unscrew the special hexagonal screws M5x20, which join the capacitor and the Bus(-). 5) Remove the Bus (-). 6) Remove the Bus(-) and the middle Bus insulator. 7) Unscrew the special hexagonal screws M5x20, which join the middle Bus and the capacitors. 8) Remove the middle Bus. 9) Remove the capacitors of their rings. Assembly of the Bus capacitors 1) Put the new capacitors on their rings 2) Insert the middle Bus (figure 7.13). 3) Screw the special hexagonal screws M5x20. 4) Insert the Bus(-) and the middle Bus insulator. 5) Insert the Bus (-) (figure 7.13). 6) Screw the special hexagonal screws M5x20, which join the Bus (-) and the capacitors. 7) Put the Bus (+) and the insulator. 8) Insert the Bus (+) (figure 7.13). 9) Screw the special hexagonal screws M5x20, which join the Bus (+) and the capacitors. Bus (-) SERVICE MANUAL 189 SD700 POWER ELECTRONICS 7.9.12 IGBTS CONNECTOR BOARD Disassembly of the IGBTs connector board. In the SD700 frame 8 there are 3 IGBTs connector boards, but in each board there are 4 upper Gate Drive connected. The use of a static grounding wrist strap and being earthed is highly required. Follow figure instructions: 7.14 while reading these 1) Disconnect the IGBT trigger wire, which connects this board and the Power board. 2) Disconnect the 3 NTC wires, which connect this board and the Upper Gate Drive. 3) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join this board and the plastic hexagonal spacers M4x40, which are inserted in the IGBT heat exchanger. 4) Disassemble the IGBTs connector board. Assembly of the IGBTs conector board. Continue to procedures. Figure 7.13. Disassembly of the Bus capacitors. 190 SERVICE MANUAL observe static safe work 1) Avoid an excessive handling of the new board. 2) Put the new board on the plastic hexagonal spacers M4x40 3) Screw the 4 Phillips screws M4x8 DIN7895H, which join this board and the plastic hexagonal spacers M4x40, which are inserted in IGBT‟s heat exchanger 4) Connect the IGBT trigger wire. 5) Connect the NTC wires SD700 POWER ELECTRONICS 7.9.13 UPPER GATE DRIVE Disassembly of the Upper Gate Drive Before proceeding, the IGBTs connector board must have been disassembled. (section 7.9.12). Follow figure instructions: 7.15 while reading these 1) Disconnect the phone wires, which connect this board to the lower Gate Drive. 2) Unscrew the Phillips screws M3x8 DIN7895H, which join this board and the hexagonal spacers M3x18. 3) Disassemble the Upper Gate Drive. Assembly of the upper Gate Drive Continue to procedures. Figure 7.15.Disassembly of the IGBT’s Connector Board observe static safe work 1) Avoid an excessive handling of the new board. 2) Put the new board on the hexagonal spacers M3x18. (figure 7.15). 3) Screw 3 Phillips screws M3x8 DIN-7895H, which join this board and the hexagonal spacers M3x18. 4) Connect the phone wires. SERVICE MANUAL 191 SD700 POWER ELECTRONICS 7.9.14. IGBT Disassembly of the IGBT Before proceeding, the upper Gate Drive board must have been disassembled. (section 7.9.14). Follow figure 7.17 (a) and figure 7.17 (b) while reading these instructions: 1) Unscrew the 4 hexagonal spacers M3x18, where the upper Gate Drive is inserted. 2) Unscrew the 2 Phillips screws M6x12 DIN7895H, which join the Snubber capacitors and the IGBTs. 3) Remove the DC Bus (section 7.9.10). 4) Remove the Snubber capacitors 5) Unscrew the 3 Phillips screws M6x20 DIN7895H, which join the IGBT and the bar where the DCCTs are screwed. 6) Remove the bar where the DCCTs are screwed. 7) Unscrew the 4 Phillips screws M5x16 DIN7895H, which join the IGBT and the heat exchanger. 8) Disassemble the IGBT. Figure 7.16. Disassembly of the Upper Gate drive Figure 7.17(a). Disassembly of the IGBT 192 SERVICE MANUAL SD700 POWER ELECTRONICS 7.9.15 SCRs Disassembly of the SCRs Before proceeding, the Upper cover (section 7.9.2), Snubber Trigger and Soft charge board (section 7.9.6), and DC Bus (section 7.9.10 ) must have been disassembled. Follow figure 7.18 and figure 7.19 while reading these instructions: 1) Unscrew the hexagonal screws M8x25 DIN933, which join the bars and the SCRs. 2) Remove the voltage measure wires after the AC choke by unscrewing the Phillips screws M4x8 DIN-7895H, which join these wires and the bars. 3) Remove the bars. Figure 7.17.(b) Disassembly of the IGBT Assembly of the IGBT Continue to procedures. observe static safe work 1) Avoid an excessive handling of the new board. 2) Take out the new IGBT of the static box. 3) Spread the thermal paste over the back of the IGBT. 4) Put the IGBT on the heat exchanger. 5) Screw the 4 Phillips screws M5x16 DIN7895H, which join the IGBT and the heat exchanger. 6) Place the DCCT Bar as it is shown in figure 7.16. 7) Insert the DC Bus (section 7.9.10). 8) Place the Snubber capacitor on the DC Bus. Figure 7.18. Disassembly of the bars SERVICE MANUAL 193 SD700 4) 5) POWER ELECTRONICS Unscrew the 2 Phillips screws M5x12 DIN7895H, which join the SCR and the heat exchanger. 7.9.16 POWER FAN Remove the SCR. Follow figure instructions: Disassembly of the Fan support 7.20 while reading 1) Unscrew the Phillips screw M4x8 DIN-7895, which joins the fan support and the fan box. 2) Unscrew the 2 Phillips screws M4x8 DIN7895H, which join the fan support and the output choke support. 3) Disconenct the fan power wire. 4) Remove the fan support. Figure 7.19. Disassembly of the SCR Assembly of the SCRs Spread the thermal paste over the back of the new SCR. 1) Insert the SCR in the heat exchanger (figure 7.16) 2) Screw 2 Phillips screws M5x12 DIN-7895H, which join the SCR and the heat exchanger. 3) Insert the bars (figure 7.16(a)) 4) Insert the voltage measure wires after the AC Choke by imscreing the Phillips screws M4x8 DIN-7895H, which join their wires and the bars. 5) Screw the Phillips screws M6x20 DIN7895H, which join the bars and the AC Choke. 6) Screw the Phillips screws M6x16 DIN7895H, which join the bars and the SCRs. 194 SERVICE MANUAL these Figura 7.20. Disassembly of the fan support SD700 POWER ELECTRONICS 7.9.17 AC CHOKE. 24VDC, 2A, 48W, 172X172 FAN Follow figure instructions: 7.21 while reading these Unscrew the 2 slotted cheese head screws M4x60 DIN-84, which join the power fan and its support. Disassembly of the AC Choke Before proceeding, the bars, which join the AC choke and the SCRs (section 7.9.15) and the Upper cover (section 7.9.2) must have been disassembled Follow figure instructions: Figure 7.21 Disassembly of the fan 7.23 while reading these 1) Unscrew the 4 Phillips screws M6x16 DIN-7895H, which join the AC choke and the chassis. 2) Remove the AC choke out of the chassis, and disconnect the 3 power wires by unscrewing the hexagonal screws M8x25 DIN-961, which join the power wires and the AC choke. 3) Disassemble the AC choke. 24VDC, 89W, 172X172 FAN Follow figure instructions: 7.22 while reading these Unscrew the 2 Phillips screws M4x12 DIN7895H, which join the power fan and its support. Figure 7.23 Disassembly of the AC choke Assembly of the AC choke Figure 7.22 Disassembly of the fan 1) Bring the AC choke near to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN-961. 2) Place the AC choke in the chassis and screw the 4 Phillips screws M6x16 DIN7895H, which join the AC choke and the chassis. Assembly of the Fan power support 1) Before introducing the fan support in the fan box, connect the fan power wire. 2) Screw the 2 Phillips screws M4x8 DIN7895H, which join the fan support and the output choke support. 3) Screw the Phillips screw M4x8 DIN-7895H, which join the fan support and the fan box. SERVICE MANUAL 195 SD700 POWER ELECTRONICS 8. Parts list. All SD700 components have a code, which give us all the information about the component. These codes have between 4 and 6 digits: rs - 1 digit: kind of component o C: Printed circuits o L: Electrics o E: Electronics o M: Mecanics o P: Power o V: Others - 2 ,3 ,4 - 5 Th digit: Revision of component. - 6 Th digit: Only in electronic components. It shows the schematic revision. on rd Th digit: number of the component 8.1. SD700 Frame 4 PCBs SD700 FRAME 380V IP54/IP20 models SD700905X SD701155X SD701505X SD701705X Control PCB E024HA E024HA E024HA E024HA Power PCB E028GJ E028GJ E028GJ E028GJ Snubbers PCB E072BB E072BB E072BB E072BB Lower Gate-Drive E088BC E088BC E089BC E089BC Upper Gate-Drive G003A G003A G003A G003A IGBTs connector PCB E083AA E083AA E083AA E083AA IGBT selection module E038BA E038BA E038BA E038BA SD700 FRAME 4 690V IP54/IP20 models SD700526X SD700626X SD700806X SD701056X Control PCB E024HA E024HA E024HA E024HA Power PCB E107BD E107BD E107BD E107BD Snubbers PCB E114BC E114BC E114BC E114BC Lower Gate-Drive E116BC E117BC E117BC Upper Gate-Drive G005A G005A G005A G005A IGBTs connector PCB E083AA E083AA E083AA E083AA IGBT selection module E038BA E038BA E038BA E038BA 196 SERVICE MANUAL SD700 POWER ELECTRONICS SCRs 380V SD700905X SD701155X SD701505X SD701705X SCR P101 P101 P101 P101 NUMBER 3 3 3 3 690V SD700526X SD700626X SD700806X SD701056X SCR P112 P115 P111 P111 NUMBER 3 3 3 3 IGBT IGBT 380V SD700905X SD701155X SD701505X SD701705X FF225R12ME3 FF225R12ME3 FF300R12ME3 FF300R12ME3 NUMBER IGBT 3 3 3 3 F225R17ME3 F225R17ME3 F225R17ME3 FF300R17ME3 690V SD700526X SD700626X SD700806X SD701056X NUMBER I (A) Capacitors 52 62 80 105 1*6 3 3 3 3 BUS CAPACITORS 380V I (A) Capacitors SD700905X SD701155X SD701505X SD701705X 90 115 150 170 1*6 1*6 1*8 1*8 690V SD700526x SD700626x SD700806x SD701056x 1*9 1*9 DCCT DCCT 380V SD700905X SD701155X SD701505X SD701705X L116 L116 L090 L090 NUMBER DCCT 3 3 3 3 690V SD700526X SD700626X SD700806X SD701056X L201 L116 L116 NUMBER 3 3 3 3 OUTPUT CHOKE Models Output choke Turns Wire section Models Output choke Turns Wire section SD700905x SD701155x SD701505x SD701705x 3 3 3 3 5 5 4 3 25 25 35 35 SD700526x SD700626x SD700806x 3 3 3 7 7 6 16 16 25 SD701056x 3 5 25 FANS 380V REFERENCE L163 L050 L086 DESCRIPTION 8414NH 24VDC, 2.4W 8314H 24VDC, 6W 6224NTDA 24VDC, 2A, 48W SD7009052 SD7009055 SD7011552 2 4 1 SD7011555 2 4 1 SERVICE MANUAL 197 SD700 POWER ELECTRONICS L119 L120 L202 L162 L160 L192 DV6224TD 24VDC, 89W 4314-180 24VDC, 9.5W 8314HU, IP54, 6W 6224NTDAU, IP54, 24VDC,48W DV6224TDU-845, IP54, 24VDC, 89W 4114NXU, IP54, 24VDC, 4,5W REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W 80X80 L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W 2 1 2 1 380V SD7015052 SD7015055 SD7017052 SD7017055 2 2 4 1 4 1 2 1 2 1 690V REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W 80X80 L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W SD7005262 SD7005265 2 SD7006262 4 1 SD7006265 2 4 1 2 1 2 1 690V REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W 80X80 L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W 198 SERVICE MANUAL SD7008062 SD7008065 SD7010562 2 4 1 SD7010565 2 4 1 2 1 2 1 SD700 POWER ELECTRONICS 8..2. SD700 Frame 5 PCBs SD700 FRAME 5 380V IP54/IP20 models SD702105X SD702505X Control PCB E024HA E024HA Power PCB E028GJ E028GJ Snubbers PCB E068BB E068BB Lower Gate-Drive E078BD E078BD Upper Gate-Drive G003A G003A IGBTs connector PCB E083AA E083AA IGBT selection module E038BA E038BA IP54/IP20 models SD701306X SD701506X SD701706X Control PCB E024HA E024HA E024HA Power PCB E107BD E107BD E107BD Snubbers PCB E113BB E113BB E113BB Lower Gate-Drive E117BC E115BC E115BC Upper Gate-Drive G005A G005A G005A IGBTs connector PCB E083AA E083AA E083AA IGBT selection module E038BA E038BA E038BA SD700 FRAME 5 690V SCRs SCR SCR P067 P067 380V SD702105X SD702505X NUMBER P111 P111 P114 3 3 690V SD701306X SD701506X SD701706X NUMBER 3 3 3 IGBT IGBT FF450R12ME3 FF450R12ME3 380V SD702105X SD702505X NUMBER 3 3 IGBT FF300R17ME3 FF450R17ME3 FF450R17ME3 690V SD701306X SD701506X SD701706X NUMBER 3 3 3 BUS CAPACITORS 380V SD702105X SD702505X I (A) 210 250 Capacitors 1*16 1*16 690V SD701306x SD701506x SD701706x I (A) Capacitors 130 150 170 1*12 1*15 1*15 SERVICE MANUAL 199 SD700 POWER ELECTRONICS DCCT DCCT DCCT 380V SD702105X SD702505X L090 L090 NUMBER 690V SD701306X SD701506X SD701706X L116 L116 L090 3 3 NUMBER 3 3 3 OUTPUT CHOKE Models Output choke Turns Wire section Models Output choke Turns Wire section SD702105x SD702505x 3 3 4 4 70 70 SD701306x SD701506x SD701706x 3 3 3 7 6 6 35 50 50 FANS REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W 80X80 L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W SD7021052 380 V SD7021055 SD7025052 2 2 4 4 SD7025055 2 2 4 4 690 V REFERENCE 200 DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W SERVICE MANUAL SD7013062 SD7013065 SD7015062 SD7015065 SD7017062 SD7017065 2 2 2 4 4 4 2 2 2 4 4 4 SD700 POWER ELECTRONICS 8.3. SD700 Frame 6 PCBs SD700 FRAME 6 380V IP54/IP20 models SD703305X SD703705X SD704605X Control PCB E024HA E024HA E024HA Power PCB E028GJ E028GJ E028GJ Snubbers PCB E068BB E068BB E068BB Lower Gate-Drive E089BC E089BC E078BD Upper Gate-Drive G003A G003A G003A IGBTs connector PCB E087AB E087AB E087AB IGBT selection module E039BA E039BA E039BA IP54/IP20 models SD702106X SD702606X SD703206X Control PCB E024HA E024HA E024HA Power PCB E107BD E107BD E107BD Snubbers PCB E113BB E113BB G005A Lower Gate-Drive E117BC E117BC E115BC Upper Gate-Drive G005A G005A G005A IGBTs connector PCB E087AB E087AB E087AB IGBT selection module E039BA E039BA E039BA SD700 FRAME 6 690V SCRs SCR P067 P067 P067 380V SD703305X SD703705X SD704605X NUMBER SCR 6 6 6 P114 P114 P114 690V SD702106X SD702606X SD703206X NUMBER 6 6 6 IGBT IGBT FF300R12ME3 FF300R12ME3 FF450R12ME3 380V SD703305X SD703705X SD704605X NUMBER 6 6 6 IGBT FF450R17ME3 FF300R17ME3 FF450R17ME3 690V SD702106X SD702606X SD703206X NUMBER 6 6 6 I (A) Capacitors 210 260 320 2*9(18) 2*12(24) 2*15(30) BUS CAPACITORS 380V I (A) Capacitors SD703305X SD703705X SD704605X 330 370 460 2*12 (24) 2*12(24) 2*16(32) 690V SD702106X SD702606X SD703206X SERVICE MANUAL 201 SD700 POWER ELECTRONICS DCCT DCCT 380V SD703705X SD704605X SD705805X L091 L092 L092 NUMBER DCCT 3 3 3 690V SD702106X SD702606X SD703206X L091 L091 L091 NUMBER 3 3 3 OUTPUT CHOKE Models Output choke Turns Wire section Models Output choke Turns Wire section SD703305x SD703705x SD704605x 6 6 6 4 4 4 70 70 70 SD702106x SD702606x SD703206x 6 6 6 9 7 9 35 35 35 FANS REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W SD7033052 380 V SD7033055 SD7037052 SD7037055 SD7046052 SD7046055 1 1 1 4 4 4 8 8 8 4 4 4 7 7 7 690 V REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W 80X80 L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W 202 SERVICE MANUAL SD7021062 SD7021065 SD7026062 SD7026065 SD7032062 SD7032065 1 1 1 4 4 4 8 8 8 4 4 4 7 7 7 SD700 POWER ELECTRONICS 8.4. SD700 Frame 7 PCBs SD700 FRAME 7 380V IP54/IP20 models SD705805X SD706505X SD707205X Control PCB E024HA E024HA E024HA Power PCB E028GJ E028GJ E107BD Snubbers PCB E068BB E068BB E113BB Lower Gate-Drive E089BC E078BD E117BC Upper Gate-Drive G003A G003A G005A IGBTs connector PCB E087AB E087AB E087AB IGBT selection module E040BA E040BA E039BA SD700 FRAME 7 690V IP54/IP20 models SD703856X SD704606X Control PCB E024HA E024HA Power PCB E107BD E107BD Snubbers PCB E113BB E113BB Lower Gate-Drive E115BC E115BC Upper Gate-Drive G005A G005A IGBTs connector PCB E087AB E087AB IGBT selection module E040BA E040BA SCRs SCR P067 P067 P114 380V SD705805X SD706505X SD707205X NUMBER 9 9 9 SCR P114 P114 690V SD703856X SD704606X NUMBER 9 9 IGBT IGBT FF300R12ME3 FF450R12ME3 380V SD705805X SD706505X NUMBER 9 9 FF450R12ME3 SD707205X 9 IGBT FF300R17ME3 FF450R17ME3 690V SD703856X SD704606X NUMBER 9 9 I (A) 385 460 Capacitors 3*12(36) 3*15(45) BUS CAPACITORS 380V I (A) Capacitors SD705805X SD706505X SD707205X 580 650 720 3*12(36) 3*16(48) 3*16(48) 203 SERVICE MANUAL 690V SD703856x SD704606x SD700 POWER ELECTRONICS DCCT DCCT L092 L123 L091 380V SD705805X SD706505X SD707205X NUMBER 3 3 3 DCCT L091 L092 690V SD703856X SD704606X NUMBER 3 3 OUTPUT CHOKE Models Output choke Turns Wire section Models Output choke Turns Wire section SD705805x 9 4 70 SD706505x SD707205x 9 9 4 4 70 70 SD703856x SD704606x 9 9 7 6 35 50 FANS 380V REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W SD7058052 SD7058055 SD7065052 SD7065055 SD7072052 SD7072055 1 1 1 6 6 6 12 12 12 6 6 6 11 11 11 690V REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W 80X80 L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W SD7038562 SD7038565 SD7046062 SD7046065 1 1 6 6 12 12 6 6 11 11 SERVICE MANUAL 204 SD700 POWER ELECTRONICS 8.5. SD700 Frame 8 PCBs SD700 FRAME 8 380V IP54/IP20 models SD708405X SD709255X Control PCB E024HA E024HA Power PCB E028GJ E028GJ Snubbers PCB E068BB E068BB Lower Gate-Drive E078BD E078BD Upper Gate-Drive G003A G003A IGBTs connector PCB E132AA E132AA IGBT selection module E040BA E040BA IP54/IP20 models SD705506X SD706606X Control PCB E024HA E024HA Power PCB E107BD E107BD Snubbers PCB E113BB E113BB Lower Gate-Drive E115BC E115BC Upper Gate-Drive G005A G005A IGBTs connector PCB E132AA E132AA IGBT selection module E040BA E040BA SD700 FRAME 8 690V SCRs SCR P067 P067 380V SD708405X SD709255X NUMBER 12 12 SCR P114 P114 690V SD705506X SD706606X NUMBER 12 12 IGBT IGBT FF450R12ME3 FF450R12ME3 380V SD708405X SD709255X NUMBER 12 12 IGBT FF450R17ME3 FF450R17ME3 690V SD705506X SD706606X NUMBER 12 12 BUS CAPACITORS 380V I (A) Capacitors SD708405X SD709255X 840 925 4*16(64) 4*16(64) 205 SERVICE MANUAL 690V SD705506x SD706606x I (A) 550 660 Capacitors 4*15(60) 4*15(60) SD700 POWER ELECTRONICS FANS REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W SD7084052 380 V SD7084055 SD7092552 SD7092555 1 1 8 8 16 16 8 8 15 15 690V REFERENCE DESCRIPTION L163 8414NH 24VDC, 2.4W L050 8314H 24VDC, 6W L086 6224NTDA 24VDC, 2A, 48W L119 DV6224TD 24VDC, 89W L120 4314-180 24VDC, 9.5W L202 8314HU, IP54, 6W 80X80 L162 6224NTDAU, IP54, 24VDC,48W L160 DV6224TDU-845, IP54, 24VDC, 89W L192 4114NXU, IP54, 24VDC, 4,5W SD7055062 SD7055065 1 SD7066062 SD7066065 1 8 8 16 16 8 8 15 15 DCCT DCCT L154 L154 380V SD708405X SD709255X NUMBER 3 3 DCCT L152 L152 690V SD705506X SD706606X NUMBER 3 3 OUTPUT CHOKE Models Output choke Turns Wire section Models Output choke Turns Wire section SD708405x SD709255x 12 12 4 4 70 70 SD705506x SD706606x 12 12 6 6 50 50 SERVICE MANUAL 206 SD700 POWER ELECTRONICS BLOCK DIAGRAM SERVICE MANUAL 207 SD700 208 POWER ELECTRONICS SERVICE MANUAL POWER ELECTRONICS SD700 SERVICE MANUAL 209 SD700 210 POWER ELECTRONICS SERVICE MANUAL POWER ELECTRONICS SD700 SERVICE MANUAL 211 SD700 212 POWER ELECTRONICS SERVICE MANUAL POWER ELECTRONICS SD700 SERVICE MANUAL 213
